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COPYRIGHT DEPOSIT. 







MANUAL 

* 

of 

“jExtoc” Batteries 

in 

Electric Vehicles 


Price, $1.00 


o > 
> > » 



The Electric Storage BatteryCo. 

• ^ 


PHILADELPHIA 


























Copyright, 1914 

by The Electric Storage Battery Co. 



AUG -8 1914 

©CI.A37G927 









CONTENTS 

(Titles of Sections) 


Receiving a New Battery. 

Operating Instructions. 

Boosting. 

Replacing a Jar. 

A Brief Outline of the Action in a Storage Battery During a Complete Cycle 
of Discharge and Charge. 

Ampere Hour Capacity. 

Rate of Discharge. 

Electrolyte. 

The Hydrometer and Its Use. 

What Is Meant by “ Sulphated. ” 

Restoring a “Sulphated ” Battery. 

Cleaning a Battery. 

Batteries in Storage. 

Complete Renewal of a Battery. 

Replacing Evaporation. 

Adjusting the Specific Gravity of the Electrolyte. 

Shipping Water and Electrolyte. 

How to Pack for Shipment. 

Hydrogen Generator for Lead Burning. 

) 

> *». 

n > 

) ) > 


Note.—T he sections are published separately and can be secured on application. 






The Electric Storage battery Co. 

PHILADELPHIA, PA. 

MANUFACTURER OF 

The “Extfce,” “Mpcap^xtfce,” “Gbtn^Extfce” and 
“11rcmclab*]£xtbe” Batteries for Electric Vehicles 


SALES OFFICES 

Philadelphia, Allegheny Ave. and 19th St. 


New York 

100 Broadway 

Detroit 

Ford Bldg. 


Boston Chicago St. Louis 

60 State St. Marquette Bldg. Fullerton Bldg. 

Cleveland Atlanta Portland, Ore. 

Citizens Bldg. Candler Bldg. Spalding Bldg. 


Rochester 

44 Cortland St. 


Los Angeles 

Pacific Electric Bldg. 


Seattle 
Colman Bldg. 


Denver 

1424 Wazee St. 


San Francisco 

118-130 New Montgomery St. 


Canada 

The Canadian General Electric Co., Ltd. 
King and Simcoe Sts., Toronto 



Form 1115 —4-’14 3500 








Receiving a New Battery 

In unpacking a battery, keep the trays right side up in 
order to avoid spilling the electrolyte (battery solution). 

After cleaning off the excelsior, etc., from the tops and 
sides of the trays, remove all the soft rubber plugs from the 
cells and see if all cells contain the proper amount of electro¬ 
lyte. 

The electrolyte should be about one-half inch above the 
top of the plates. 

If the electrolyte is uniformly below the proper level, add 
enough distilled or other pure water to bring the level to the 
proper height. 

If the level of the electrolyte in some cells is found below 
the top of the plates, it is due to loss of electrolyte. 

If due to the tray having been turned over during ship¬ 
ment, the excelsior around the top of the tray will be wet, and 
some acid would be spilled from all of the cells in that tray. 
In this case, replace the amount spilled by filling the low cells 
to the proper height with chemically pure electrolyte of about 
1.250 specific gravity (7 parts of pure water and 2 parts pure 
sulphuric acid by volume). 

If the electrolyte in a cell is low, due to a broken jar, the 
bottom of the tray will be wet although the excelsior around 
the top of the tray may be dry. Replace the broken jar and 
add sufficient acid to make up for the amount lost. 

If it is found, after replacing the broken jar and giving the 
battery an equalizing charge, that the gravity does not come 
to approximately 1.275, it is due to not having replaced the 
same amount of acid as was spilled. To adjust this, draw 
off some of the electrolyte from the top of the cell and add 
water or 1.300 acid as required to bring the specific gravity to 
between 1.270 and 1.280. 

Put the battery on charge at the low rate given on the 
name plate of each tray. Charge at about this rate until all 
of the cells gas uniformly. Reduce the current to about one- 
half and charge for about three hours longer, when the battery 
will be ready to put into service. 

It is advisable, however, before putting the battery into 
service to take and record the specific gravity of the electro- 

1 


Unpacking 


Inspecting 

Individual 

Cells 


Electrolyte 
Lost in 
Shipment 


Adjusting the 

Electrolyte 

Replaced 


Freshening 

Charge 



Manual of Batteries in Electric Vehicles 


lyte of each cell. These readings serve to indicate if the cells 
Record are i n a normal condition, also to show approximately how 
Gravity of high the gravity should come at the completion of subsequent 
Each Cell we eklv equalizing charges. The temperature of one or more 
of the cells should be recorded. 

When installing the trays in the battery compartment, see 
Installing that they are seated firmly and evenly without any undue 
Battery in twisting or straining. Then fasten the trays firmly in position 
^ ar by means of the hold-downs provided for this purpose. 

The instruction book sent to owners who do their own 
charging is as follows: 


General 

Discharge 

Unnecessary 

Charging 

Standing 

Discharged 

Caution 


Replacing 

Evaporation 

Charging 

Kind of 
Current 

Polarity 

Ventilation 


INSTRUCTION BOOK 

For the Operation of the 

“EXt&e” Vehicle Batteries 

The battery may be discharged, without injury to the 
plates, at any rate of current it will deliver. The battery 
should be promptly recharged upon reaching 1.7 volts per cell 
when delivering the normal service rate stamped on the name 
plate. 

It is uneconomical to charge the battery more frequently 
than once a week unless the service requires it. 

A battery should never stand completely discharged. 

Keep naked flames (match, candle or lighted cigar) away 
from the battery at all times. 

Keep the level of the electrolyte always above the top of 
the plates by replacing evaporation with pure water (never any¬ 
thing else) to a height of one-half inch (not more) above top 
of plates. This should be done before a charge. 

Use only direct current (never alternating current) for 
charging; if only alternating is available, apparatus must be 
procured to change it to direct. 

The positive terminal of the battery must be connected to 
the positive wire of the charging circuit. 

Open the battery compartment; ventilation on charge is 
necessary. 


2 





Regular Charging Instructions 


The charge for any of the batteries of the * 'lExifte' ’ family 
may be started at any available rate of current within the 
capacity of the charging apparatus, wiring and connections. 
The only limitations of the charging rate, at any period of 
the charge, are the gassing of the cells and the temperature 
of the electrolyte. 

Stamped on the name plate of the battery are two charg¬ 
ing rates, the lower of which is the “finishing” rate. The 
higher figure is only given as being, under usual conditions, a 
satisfactory rate at which the greater part of the charge may 
be given. 

Whenever the cells begin to give off gas, lower the rate; 
when the current has been reduced in one or more steps to the 
“finishing rate” given on the name plate, continue at this rate 
until all the cells in the battery are gassing uniformly. If at 
any time during the charge the temperature of the electrolyte 
reaches 110° F., the current must be reduced or the charge 
temporarily stopped. A full or partial charge can, in case of 
necessity, be given the battery in a very short time by starting 
the charge at a high rate. Particular care must be taken to 
reduce the current whenever gassing begins. 

Once each week, and immediately after the battery has 
received its regular charge, give it an equalizing charge of not 
less than three hours at one-half the “finishing” rate. This 
is particularly important when a battery is not charged every 
day. 

An ampere hour meter, when used, should be set or 
adjusted to give the battery the amount of charge necessary 
to produce the uniform gassing at the “finishing” rate, which 
indicates the completion of a regular charge. This amount is 
usually from 10 to 15 per cent, in excess of the discharge. 
The weekly equalizing charge should be given irrespective of 
the ampere hour meter. 

Once a month and immediately after the regular equaliz¬ 
ing charge check the condition of the battery by hydrometer 
readings. If the specific gravity of the electrolyte of any cell 
is higher than 1.300 or lower than 1.250, the cause should be 
promptly investigated and corrected. 

3 


Charging 

Rates 

Wide Range 
of Rates 


Usual Rates 


Gassing 

Reducing 
the Current 

Finishing 

Rate 

High 

lemperatures 

Quick 

Charging 


Egualizing 

Charge 


Ampere 
Hour Meter 


Hydrometer 

Readings 



Manual of Batteries in Electric Vehicles 


Pilot Cell 


Battery Idle 


Leaking Jar 


Periodical 

Inspection 


“Exibc” 

Inspection 

Service 


Since, during a discharge, the drop in specific gravity of 
the electrolyte is directly proportional to the amount of the 
discharge, one of the cells of the battery may be regularly 
used as a “pilot cell” for taking hydrometer readings, which 
are of value to indicate the state of charge or discharge of the 
battery at any time. 

When a battery is to remain idle for a period of not to 
exceed four months, see that it is in good condition and give it 
an equalizing charge immediately before the idle period and 
again immediately before going into service. If more than 
four months, send it to your battery man. 

If a jar develops a leak, have it replaced at once. 

Decreasing specific gravity throughout the battery ( when 
not due to insufficient charging), indicates that sediment is 
accumulating in the bottom of the jars. An inspection should 
be made by a competent battery man when the specific 
gravity of th e fully charged battery is below 1.250. 

In territories covered by The Electric Storage Battery , 
Company’s Service Department, the Company will be glad 
to have an inspector, on one of his periodical trips, make an 
inspection free of charge. 

If advice is desired, which cannot be obtained locally, 
write, giving full particulars and especially all markings on the 
name plate on the battery trays, to 


THE ELECTRIC STORAGE BATTERY CO. 
Service Department 

333 W. 35th St. Chicago, Ill. 


or to 


THE ELECTRIC STORAGE BATTERY CO. 
Allegheny Ave. and 19th St. 
Philadelphia, Pa. 


or to 


THE ELECTRIC STORAGE BATTERY CO. 
590 Howard Street, 

San Francisco, Cal. 

4 


Form 1113 A—4-’14—3500 



Boosting 

The term “boosting” as applied to vehicle batteries may 
be defined as “auxiliary charging.” It usually implies a par¬ 
tial charge given in a comparatively short time and at cur- Definition 
rent rates higher than normal. A battery may be boosted 
when fully discharged or when only partially discharged, 
although the latter case is more usual. 

Boosting is particularly adapted to commercial vehicles, When 
and is applicable when the capacity required from a battery Applicable 
is greater than the normal output for which it is designed. 

Such conditions may arise from the necessity of doing extra 
work, as in the case of heavy delivery requirements during 
the Christmas rush or from bad weather or heavy roads. A 
battery may have ample capacity to give the desired mileage 
under normal conditions and by boosting can be made to meet 
extra demands. 

Boosting renders it unnecessary to carry around every 
day a battery capable of giving the special capacity occa¬ 
sionally required. 

In considering boosting a battery, it should always be 
remembered that the limits for charging rate at any time are 
the gassing and temperature of the cells. The temperature 
should not be allowed to exceed 110° F. A battery on charge 
is absorbing all the current when it is not gassing, regardless 
of the rate of current. A battery in a considerably discharged 
condition will absorb current at a very high rate with neither 
gassing nor undue rise in temperature. A battery which is 
very little discharged will absorb current only at a very low 
rate. 

There are several methods by which boosting can be 
practically applied to batteries of the “lExifte” types, and 
the method to be chosen depends upon the available charging 
facilities and other conditions in individual cases. 

1. Constant Potential (Fixed Voltage). Where condi- Constant 
tions permit, this is probably the ideal method since it is Potential 
entirely automatic and requires little attention. It is applic¬ 
able where there is available a voltage of about 2.3 per cell 
of battery, for example, 110 volts for 48 cells, and the charg- 

1 









r 

( 


Manual of “TExtDe” Batteries in Electric Vehicles 


ing equipment and wiring have sufficient capacity for current 
rates up to four or five times the usual charging rates. Where 
the voltage of the charging source is higher than 2.3 per cell, 
it may be cut down by placing in the charging circuit coun¬ 
ter E. M. F. cells, figured at 3 volts each. (A rheostat will 
not accomplish the desired result.) Thus, if the line voltage 
is 110 and the battery consists of 40 cells, there will be 18 
volts to be taken up by counter cells and six of these will 
be required. 

With the charging voltage thus fixed at about 2.3 volts 
per cell, a battery in any state of discharge can be put on 
charge and will receive in a short time a large proportion of 
the amount of discharge which has been taken out. The cur¬ 
rent will automatically taper from a high rate at the start to 
a low rate toward the finish, and no attention or adjustment 
is required. Under normal conditions, the cells will not reach 
the free gassing point or excessive temperature, and therefore 
no harm will result from their being inadvertently left on 
charge longer than necessary. 

Approximate 2. Approximate Constant Potential, with Fixed 
Constant Resistance in Series with the Battery. When the charging 
Potential equipment and wiring have sufficient capacity for high cur¬ 
rents as above, but the voltage of the charging circuit is too 
high (above 2.3 per cell) and counter E. M. F. cells are not 
available for cutting it down, the following method may be 
Rheostat use d providing the time is limited to one hour or less: Con¬ 
nect a rheostat in series with the battery with all the resist¬ 
ance in circuit. The rheostat must be capable of carrying 
currents up to four or five times the usual starting charge 
rate. After closing the circuit, read the voltage at the battery 
terminals and cut down the charging resistance until the bat-' 
tery voltage corresponds to the voltage given in the following 
table for the appropriate number of cells. The circuit can 
then be left without further adjustment for an hour or less 
and the current will taper off as the voltage of the battery 
rises. This table is fi.gvred for a line voltage of 110-120, and the 
voltages given are too high for a boost of more than one hour's 
duration. 


Counter 
E. M. F. Cells 


Tapering 

Current 


2 





Boosting 


Number of Cells 


Voltage at Battery Terminals 


48 

44 

42 

40 

38 


110 

98 

92 

86 

80 


3. Constant Current. In some cases it is more con- Constant 
venient to give a boost at a constant rate of current, and as Current 
there is generally a limited time available, it is desirable to 
know under any given conditions what rate is safe. A con¬ 
venient rule for determining this is as follows: 


ampere hours already discharged 


Charging current (amperes) 


Formula 


1 +hours available for boosting. 


This gives the maximum current which can be used for the 
time specified without reaching the gassing point The 
method is most conveniently applied where the car is 
equipped with an ampere hour meter. 

In order to save calculations, we give a table based on 
this formula. Knowing the ampere hours discharged and 
the time available for boosting, the proper charging current, 
irrespective of the size of battery, can be read off at a 
glance. 

When any considerable time for boosting is available 
and it is convenient to regulate the current at intervals, a 
greater amount of charge can be put in by dividing the time 
into several periods and finding the current for each period 
separately. 

One of the methods outlined above is almost sure to 
meet the requirements of any individual case; but whatever 
method is used, remember: 

To obtain the advantages of boosting without injury to 
the battery, avoid gassing and keep the cell temperature 
below 110 degrees F. 


3 











Manual of “lExiDe” Batteries in Electric Vehicles 


CONSTANT CURRENT BOOSTING RATES 


TIME AVAILABLE FOR BOOSTING 


Ampere Hour 
Discharged 

34 hour 

Amperes 

34 hour 

Amperes 

hour 

Amperes 

1 hour 

Amperes 

t/3 

>- t/i 

3 <b 

2 S 

5 1 ! 

1/4 hours 

Amperes 

1% hours 

Amperes 

2 hours 

Amperes 

10 

8 

6 

5 

5 

4 

4 


3 

3 

20 

16 

13 

11 

10 

9 

8 


7 

6 

30 

24 

20 

17 

15 

13 

12 

11 

10 

40 

32 

26 

23 

20 

18 

16 

14 

13 

50 

40 

33 

28 

25 

22 

20 

18 

16 

60 

48 

40 

34 

30 

26 

24 

22 

20 

70 

56 

46 

40 

35 

31 

28 

25 

23 

80 

64 

53 

45 

40 

35 

32 

29 

27 

90 

72 

60 

51 

45 

40 

36 

33 

30 

100 

80 

66 

57 

50 

44 

40 

36 

33 

110 

88 

73 

63 

55 

49 

44 

40 

37 

120 

96 

80 

68 

60 

53 

48 

43 

40 

130 

104 

87 

74 

65 

58 

52 ' 

47 

43 

140 

112 

93 

80 

70 

62 

56 

51 

47 

150 

1 120 

100 

86 

75 

67 

60 

54 

50 

160 

128 

106 

91 

80 

71 

64 

58 

53 

170 

136 

113 

97 

85 

75 

68 

62 

57 

180 

144 

120 

103 

90 

80 

72 

65 

60 

190 

152 

127 

108 

95 

84 

76 

69 

63 

200 

160 

133 

114 

100 

89 

80 

73 

67 

210 

168 

140 

120 

105 

93 

84 

76 

70 

220 

176 

147 

126 

110 

98 

88 

80 

73 

230 

184 

153 

131 

115 

102 

92 

84 

77 

240 

192 

160 

137 

120 

106 

96 

87 

80 

250 

200 

167 

143 

125 

111 

100 

1 

91 

83 


Explanation. —In the left hand column, find the figure nearest to 
the ampere hours discharged from the battery; follow across to the column 
headed by the available time. The figure at this intersection is the 
current to be used. 

Example. —Ampere hour meter reading, 103 ampere hours dis¬ 
charged; time available for boosting, one hour. Start at 100 in the left 
hand column; follow across to the column headed 1 hour and find 50, 
which is the current to be used. 

In general, the above method will not put in as much 
charge in a given time as the constant potential method, and 
the current must not be continued beyond the time for which the 
rate is figured, as injurious gassing and heating will result. 

4 


Form 1113 B—4-T4—3500 











































Replacing a Jar 


To replace a broken jar, where the connector puller is not 
available, drill the connectors centrally in the top of the en¬ 
larged ends joined to the two cells adjacent to the jar which 
is to be replaced. A % inch wood bit is suitable (Fig. 1). 
Before removing the cell, mark one of its connectors in order 
to replace the cell properly after the jar has been changed. 

Lift the complete cell, including jar, out of the tray 
(Fig. 2) and with an ordinary gasoline blow torch warm the 


Removing 

Connectors 

Mark Polarity 


Part of connector cut away Cell to be Method of drilling 

: to show depth of drilling removed « connector 



Fig. 1. Drilling off Connectors 


sides of the jar around the top to soften the sealing compound 
around the cover (Fig. 3). Grip the jar between the feet, 
take hold of the two connectors and pull the element almost 
out of the jar (Fig. 4); then grip the element near the bot¬ 
tom (Fig. 5) in order to keep the plates from flaring out while 
transferring to the new jar, taking care not to let the outside 
plates start down over the outside of the jar (Fig. 6). After 

1 


Removing 
Element 
from Jar 

Installing 
Element in 
New Jar 










Reburning 

Connectors 


Manual of “JExtDe” Batteries in Electric Vehicles 

the element is in the new jar, reseal the cell by pressing the 
sealing compound into place with a hot putty knife. 

Fill the cell with 1.250 electrolyte to the proper height. 



Fig. 2. Lifting Cell out of Tray 


Before replacing the connector, clean both the post and 
the inside of the eye of the connector by scraping smooth with 
a knife blade. When the connector has been placed in posi¬ 
tion, tap it down firmly over the post to insure good contact. 

To complete the connection, melt the lead of the connector 
and the post at the top so that they will run together, and 
while the lead is still molten, melt in more until the eye of the 

2 






Replacing a Jar 



Fig. 3. Softening Sealing Compound on Cell 



Fig. 4. Lifting Element out of Jar by Hand 

3 













Manual of “JExiDe” Batteries in Electric Vehicles 



Fig. 5 Gripping Element near Bottom to 
Keep Plates from Flaring out 



Fig 6. Installing Element in Jar 

4 












Replacing a Jar 



Lead 

burning 

strip 


Fig. 7. Reburning Cell with Carbon Arc 


connector is filled. This is called “lead burning," and can 
best be accomplished by means of a regular hydrogen flame if 
available; or with a carbon arc burning outfit, as shown in 
Fig. 7, or an ordinary soldering iron heated red hot and used 
as shown in Fig. 8. 

Never use soldering flux of any kind. 

Put the battery on charge, and when the cells begin to 
gas freely reduce the current to half the “finishing" rate given 
on the name plate and charge at this rate as long as there is any 
rise in gravity in this or any of the other cells. The maximum 
gravity has been reached when there has been no rise for a 
period of three hours. If the gravity of this one cell is then 
above 1.280, draw off some of the electrolyte and replace with 


Adjusting 
Gravity of 
Electrolyte 









Manual of “lExifte” Batteries in Electric Vehicles 


pure water. If the gravity is below 1.270, draw off some of 
the electrolyte and replace with 1.300 electrolyte. After 
putting in the 1.300, allow the battery to charge for about half 
an hour at a rate sufficient to cause gassing, which will cause 
the stronger acid to become mixed with the rest of the electro¬ 
lyte in the cell. 


Red hot 
soldering 
iron, not 
tinned 



Fig. 8. Reburning Cell with Soldering Iron 

6 


Form 1113 C—4-’ 14—3500 









A Brief Outline of the Action in a 
Storage Battery During a Complete 
Cycle of Discharge and Charge 

A storage battery consists of one or more cells. 

A cell consists essentially of positive and negative plates 
immersed in electrolyte. 

The electrolyte of the vehicle cell consists of a 

mixture of sulphuric acid and water which, when the cell is 
fully charged, should have a gravity of 1.270 to 1.280. 

When a cell is put on discharge, the current is produced 
by the acid in the electrolyte going into and combining with 
the lead of the porous part of the plates called “active mate¬ 
rial.” In the positive plate the active material is lead peroxide, 
and in the negative is metallic lead in a spongy form. 

When the sulphuric acid in the electrolyte combines with 
the lead in the active material, a compound, lead sulphate, is 
formed. 

This lead sulphate is formed in the same way that sul¬ 
phuric acid on the copper wiring or terminals forms “copper 
sulphate,” or acid on the iron work of the car forms “iron 
sulphate.” In this connection, it is noticeable that a compara¬ 
tively large mass of “copper sulphate” or “iron sulphate” is 
formed on the metal work of the car when only a small quantity 
of the metal is eaten away. In the same manner, the sul¬ 
phuric acid of the electrolyte combines with lead in the plates 
forming lead sulphate, which, on account of its increased vol¬ 
ume, fills the pores of the active material. 

As the discharge progresses, the electrolyte becomes 
weaker by the amount of acid that is used in the plates, 
producing the electric current and incidentally producing the 
compound of acid and lead called “lead sulphate.” This 
sulphate continues to increase in quantity and bulk, thereby 
filling the pores of the plates. As the pores of the plates 
become thus filled with the sulphate, the free circulation of 
acid into the plates is retarded; and, since the acid cannot 
then get into the plates fast enough to maintain the normal 

1 


General 


Formation of 
Lead Sulphate 


Retarding 
Circulation 
of Acid 


Manual of “ESxiDe” Batteries in Electric Vehicles 


Drop in 
Voltage 

End of 
Discharge 


Drop in 
Specific Grav¬ 
ity During 
Discharge 


Charging 


Action of 
the Current 


Object of 
Charging 


action, the battery becomes less active, as is indicated by a 
rapid drop in voltage. Experience teaches that at the normal 
discharge rate the voltage will begin to drop rapidly very soon 
after reaching 1.8 per cell. It is therefore advisable to stop 
the discharge when the voltage has dropped as low as 1.7 per 
cell, and a battery should not normally be discharged below 
this point. 

During a normal discharge the amount of acid used from 
the electrolyte in “JExiDe” types of cells will cause the 
gravity to drop 100 to 150 points. Thus, if the gravity of a 
fully charged cell is 1.275, it will, at the end of discharge, be 
between 1.175 and 1.125, depending upon the type of cell. 
The battery should be put on charge before it is discharged 
below this point. 

To charge, cause direct current to pass through the cells 
in a direction opposite to that of discharge. This current, 
passing through the cells in the reverse direction, will reverse 
the action which took place in the cells during discharge. It 
will be remembered that during discharge the acid of the 
electrolyte went into and combined with the active material 
filling its pores with sulphate and causing the electrolyte to 
become weaker. Reversing the current through this sulphate 
in the plates restores the active material to its original condi¬ 
tion and returns the acid to the electrolyte. Thus, during 
charge, the electrolyte gradually becomes stronger as the sul¬ 
phate in the plates decreases, until no more sulphate remains 
and all the acid has been returned to the electrolyte, when 
it will be of the same strength as before the discharge and the 
same acid will be ready to be used over again during the next 
discharge. Since there is no loss of acid, none should ever be 
added to the electrolyte. 

# 

Remember this: The acid absorbed by the plates during 
discharge is, during charge, driven from the plates by the charging 
current and restored to the electrolyte. This is the whole object of 
charging. 

It has been said that every man has a different method of 
charging a storage battery, but in fact all methods are essen- 

2 





Brief Outline of Action of a Storage Battery 


tially the same in principle; that is, to pass direct current 
through the cells in the right direction. In the use of this 
current, there are only two points to be considered—rate in 
amperes and time. 

The rate in amperes is limited by the state of discharge. 
When a battery is fully discharged, at which time the plates 
contain the greatest amount of sulphate, it can utilize current 
at the highest rate. As the charge progresses and the amount 
of sulphate in the plates decreases, they can no longer utilize 
current at the same rate and the current should be reduced. 
The time at which to reduce the current is when the cells 
begin to give off gas. 

The gassing of a cell is a feature of charging which has 
been very little regarded, but is of great importance. Gassing 
shows at any time whether or not the charging rate is too high. 

Current passing through an electrolyte will always do 
something. It will always do the easiest thing first. When 
current is passed through a discharged cell, the easiest thing is 
to decompose sulphate. As there is a comparatively large 
amount of sulphate in a fully discharged cell, a high rate of 
current can be used, but as the amount of sulphate decreases 
a point will be reached at which there will not be sufficient 
sulphate remaining ill the plates to ut-ilize all the current pass¬ 
ing through. The excess current will then begin to do the 
next easiest thing, which is to decompose the water of the 
electrolyte, producing gas and, therefore, when the cells begin 
to gas freely, it indicates that current is being passed through 
the cells at too high a rate and the current should be lowered 
sufficiently to stop the gassing. As the charge is continued at 
the lower rate, the remaining sulphate will continue to 
decrease in amount until there is not sufficient left to utilize 
this rate of current and the cells will again begin to gas. The 
current should be lowered each time the gassing begins. 
When the cells begin to gas freely at a very low rate, it indicates 
that there is no sulphate remaining, so that even this very low 
rate of current cannot be utilized, and the charge is completed. 

The sulphating which takes place during an ordinary 
discharge is entirely normal. If, however, charging is neg¬ 
lected, the sulphate increases and becomes hard and the plates 

3 


Different 
Methods of 
Charging 


Limit of 
Charging Rate 


Gassing 


Cause 
of Gassing 


What Gassing 
Indicates 


Normal 

Sulphate 






Abnormal 

Sulphate 


Equalizing 

Charge 


Manual of “JExifcC” Batteries in Electric Vehicles 


lose their porosity and are not easily charged; this is the 
abnormal condition usually referred to as “sulphated.” 

In ordinary charging, there is not sufficient time to con¬ 
tinue the charge until absolutely all the sulphate is removed. 
To prevent any possibility of the small remaining amount of 
sulphate increasing and becoming hard, a weekly equalizing 
charge is given. 


Form I 113 D—l-’U—3500 


4 






Ampere Hour Capacity 


The ampere hour capacity of a battery, the cells of which 
are connected in one series, is the same as that of a single cell 
in the series. 

The ampere hour capacity of a cell depends upon the 
number of plates of a given type. 

The ampere hour capacity of a plate depends upon the 
amount of available active material it contains. 

It may be well to explain here what is meant, by available 
active material. Since acid and lead combine with each other 
in a definite proportion in producing current, it might seem 
possible to have acid and lead in a cell in such quantities that 
both would be completely exhausted. Toward the end of 
the discharge, however, the electrolyte would be so weak that 
it would not be capable of producing current at a sufficient 
rate for any practical purpose. For this reason, it is necessary 
to have in the electrolyte acid in excess of the amount actually 
used in the plates during discharge. 

Similarly, if all the active material were combined with 
acid, the plates would lose their porosity and conductivity, 
and an excess of lead active material is likewise provided. 

It is customary to make both outside plates in a cell 
negatives. The cells contains, therefore, an odd number of 
plates and the capacity is fixed by the number of positives. 

On this basis, the following table shows the rated capaci¬ 
ties of the several types of M. V. *‘l£XtDC ,t plates: 


TYPE 

Discharge 
Rate per 
Positive Plate 

Time 
in Honrs 

Ampere Hours 
per 

Positive Plate 

“lExibe”. 

7 

4 

28 

“1Ironclab=iExibc”.... 

7 

4.5 

31.5 

< “JHv>captf]£x^De ,, . 

5.5 

5 

2 7 .’5 

“EbmsJExiDe”. 

4.125 

6 

24.75 


A. H. Capacity 
of a Battery 


A. N. Capacity 
of a Cell 

A. H. Capacity 
of a Plate 


Available 

Active 

Material 


Capacities 
of M. V. 
“lExit'e” 
Plates 


1 

















Time in Hours /5 minutes per division I Volts per Cell 


Manual of "jExi&e’' Batteries in Electric Vehicles 


f 



A 5 6 7 ^ 8 9 

Amperes per Positive Plate 


? 




































































































































































































































































































































































































































































































































































































































































































































































































































































































































Ampere Hour Capacity 



13 14 15 16 17 18 19 20 21 22 23 

Amperes per Positive Plate E.S.B.Co.769 


3 


MINUTE PER DIVISION Volts per Cell 

































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































r 


Rate of Discharge 

Since the current is produced by the action of sulphuric 
General ac i(j combining with lead in the plates, the rate at which the 
acid can get to the material determines the maximum rate at 
which current can be produced. For instance, if the same 
amount of material in a nine plate cell were made into only 
two plates, one positive and one negative, the ampere hour 
capacity at a sufficiently low rate would be just the same as if 
this material were divided into four positives and five negatives. 
At ordinary rates of discharge, however, the acid could not 
get to the material of such a thick plate fast enough to main¬ 
tain the rate for the required time. If these same thick plates 
were split into thinner plates, the acid could much more 
readily get to that portion of the material which in the thick 
plates was farther removed from the surface, and current could 
therefore be produced more rapidly. It is apparent that, 
within certain limits, the material can be divided into thinner 
and thinner plates to maintain the desired rate of discharge. 

Thin Plates The thinner the plates the shorter the life under ordinary 
conditions of service; therefore, it is always advisable to use 
Thick Plates as thick a plate as the necessary capacity at the required rate 
of discharge will permit. 

The curves on pages 2 and 3 show the capacity and 
voltage characteristics of the various “TExt^C” types at 
different rates of discharge. 


Form 1113 E—1-’14—3500 



4 




Electrolyte 

Electrolyte, as used in all “JSXt&C” types of batteries, 
consists of a mixture of pure sulphuric acid and distilled or 
other pure water. 

Concentrated sulphuric acid is a heavy, oily liquid having 
a specific gravity of about 1.835. A battery will not operate 
if the acid is too strong, and it is therefore diluted with suf¬ 
ficient pure water to bring it to a gravity of about 1.275 for a 
fully charged battery. 

While a battery is being discharged, the electrolyte 
becomes weaker, as part of the acid is combined in the plates 
in producing the current. 

This weakening of the electrolyte causes the gravity to 
drop 100 to 150 points during a complete discharge. During 
the charge, this acid is returned to the electrolyte, thus increas¬ 
ing its strength until it again reaches the normal gravity. 
There being no loss of acid, it is never necessary during normal 
service to add any acid to a battery. Of course, if a battery 
is upset and acid spilled, or if a jar is broken and acid leaks 
out, it should be replaced. In the event of any cells having 
been flooded, by wash water or other cause, provision should 
immediately be made to prevent a recurrence. Unless acid is 
actually 'known to be lost out of a cell , none should ever be added 
during the entire life of a battery. The amount of acid lost in 
spray is immeasurably small and should be neglected. 

The gravity of the electrolyte need not necessarily be 
exact, but in a fully charged battery a range from 1.250 to 
1.300 is permissible. 

Both the water and the sulphuric acid used in making 
electrolyte should be chemically pure to a certain standard. 
This is the same standard of purity as is usually sold in drug 
stores as “CP" (chemically pure) or by the chemical manu¬ 
facturers as “battery acid." 

In this connection, the expression “chemically pure" acid 
is often confused with acid of “full strength." An acid may 
be of full strength (approximately 1.835 sp. gr.) and at the 
same time chemically pure. If this chemically pure acid of 
full strength be mixed with chemically pure water, the mixture 
would still be chemically pure, but not of full strength. On 

1 


Composition 


Concentrated 

Sulphuric 

Acid 


Drop in Spe¬ 
cific Gravity 


Chemically 

Pure 

Electrolyte 




Manual of < ‘jExi£>e ,r Batteries in Electric Vehicles 


the other hand, if a small quantity of some impurity be 
introduced into chemically pure acid, it would not materially 
reduce the strength, but would make it impure. 

The usual method of determining the strength of electro¬ 
lyte is by taking its specific gravity. This method is possible 
on account of the fact that sulphuric acid is heavier than 
water. Therefore the greater the proportion of acid contained 
in the electrolyte the heavier the solution or the higher its 
gravity. 

By specific gravity is meant the relative weight of any 
Specific substance compared with water as a basis. Pure water, there- 
Gravity fore, is considered to have a gravity of 1. One pound of 
water is approximately 1 pint. An equal volume of ordinary 
chemically pure sulphuric acid weighs 1.835 pounds. It 
therefore has a specific gravity of 1.835 and is spoken of as 
“eighteen thirty-five." As it is customary to carry the 
gravity readings out three decimal places, the gravity of water 
which is 1, is written 1.000 and spoken of as “one thousand.” 

Since electrolyte, like most substances, expands when 
Temperature h eate d, its specific gravity is affected by a change in temper- 
Correction ature. If electrolyte has a certain gravity at a temperature 
of 70° F. and be heated, the heat will cause the electrolyte to 
expand and, although the actual strength of the. solution will 
remain the same as before heating, yet the expansion will 
cause it to have a lower gravity, of approximately one point 
(.001) for each three degrees rise in temperature. For instance, 
if electrolyte has a gravity of 1.275 at 70° F. and the tempera¬ 
ture be raised to 73° F., this increase in temperature will cause 
the electrolyte to expand and the gravity to drop from 1.275 
to 1.274. On the other hand, if the temperature had been 
lowered from 70° to 67° F., this would have caused the gravity 
to rise from 1.275 to 1.276. Since change of temperature does 
not alter the actual strength of the electrolyte, changing its 
gravity only, the gravity reading should be corrected one point 
for each three degrees change in temperature. For conve¬ 
nience, 70° F. is considered as normal, from which point the 
corrections are made. 


2 




Electrolyte 


The following table shows the parts of water by volume, 
the parts of water by weight and the percentage of acid to 
water to produce different gravities: 

>vt •?, 

TABLE OF SULPHURIC ACID SOLUTIONS 


Based on one part acid of 1.835 sp. gr. at 60° F. 


Specific Gravity of 
Solution (70° F.) 

Parts of Water to One Part Acid 

Percentage of 
Sulphuric Acid 
in Solution 

By Volume 

By Weight 

1.100 

9.8 

5.4 

14.65 

1.110 

8.8 

4.84 

16. 

1.120 

8. 

4.4 

17.4 

1.130 

7.28 

3.98 

18.8 

1.140 

6.68 

3.63 

20.1 

1.150 

6.15 

3.35 

21.4 

1.160 

5.7 

3.11 

22.7 

1.170 

5.3 

2.9 

24. 

1.180 

4.95 

2.7 

25.2 

1.190 

4.62 

2.52 

26.5 

1.200 

4.33 

2.36 

27.7 

1.210 

4.07 

2.22 

29. 

1.220 

3.84 

2.09 

30.2 

1.230 

3.6 

1.97 

31.4 

1.240 

3.4 

1.86 

32.5 

1.250 

3.22 

1.76 

33.7 

1.260 

3.05 

1.66 

35. 

1.270 

2.9 

1.57 

36.1 

1.280 

2.75 

1.49 

37.3 

1.290 

2.6 

1.41 

38.5 

1.300 

2.47 

1.34 

39.65 

1.320 

2.24 

1.22 

42. 

1.340 

2.04 

1.11 

44.1 

1.360 

1.86 

1.01 

46.3 

1.380 

1.7 

.92 

48.4 

1.400 

1.56 

.84 

50.5 

1.450 

1.25 

.68 

55.5 

1.500 

1 . 

.55 

60.15 

1.550 

.8 

.44 

64.6 

1.600 

.639 

.348 

69.12 

1.650 

.497 

.27 

73.32 

1.700 

.369 

.201 

77.6 

1.750 

.248 

.135 

82.1 

1.800 

.1192 

.0646 

87.5 

1.835 

0 . 

0 . 

93.19 


Table of Sul¬ 
phuric Acid 
Solution 


3 



















Manual of “Bxtfce” Batteries in Electric Vehicles 













































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































Electrolyte 



(WoOZ.) afiiojpaiz jo fyiAvjc) wjisadg poJisaQ 


5 


Founds of* 1.300 Acid Required.(70 c Fab.) E».SBCo.758 





























































































































































































































































































































































































































































































































































































































































































































































































Manual of M 3£xi&e” Batteries in Electric Vehicles 



-Specific Gravity 


E. 


3 DO 
S, B. Co. 76d 


6 









































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































































The Hydrometer and Its Use 


Fig. 1 shows the several types of hydrometers in gen¬ 
eral use, and parallel with the stem of each is shown a view 
of the scale contained in the stem. 





EZ 




& 


c 


/ 


S 


TYPE 

VH 

Hygrometer 




r\ 

!§: 


r 



§j 



3 

=8; 


if 



if 


r 


m 


m 


m 


/ 


a= 

O: 


n 


- 

O : 


y= 


i 

1 

f 


\ 


Type 

Hydnorn^tei 



Types in 
General Use 


Fig. 1 


Outlines of Hydrometers 

7 


E. S. B. Co. 761 
































































































Manual of “jSxifte" Batteries in Electric Vehicles 


Type V-l is more commonly used in connection with 
vehicle types of batteries. Type S-l is used with automo¬ 
bile starting and lighting batteries, and Type M is used in 
battery rooms where more accurate reading is desired. 

It is necessary to have the electrolyte in a suitable vessel 
in which to place the hydrometer. The simpler form of 
. . vessel is a glass cylinder of sufficient diameter to allow the 
Vessel hydrometer to float freely without touching the sides and a 
little higher than the total length of the hydrometer. The hy¬ 
drometer is placed in the cylinder and some acid is drawn 
from the cell with a syringe and placed in the cylinder, putting 
in just sufficient to float the hydrometer off the bottom of 
the cylinder. 

Cylinder This is shown in Fig. 2, and is sufficiently convenient 
where only occasional readings are taken, but where it is 



Fig. 2. Acid Testing Set 

desired to take frequent readings it is found more convenient 
Syringe to have a hydrometer placed inside of a glass barrel with 
a rubber bulb on the top end and a suitable nozzle on the 
lower end (Fig. 3). By squeezing the bulb, inserting the 
nozzle into the electrolyte and releasing the bulb, acid is 

8 











The Hydrometer and Its Use 



drawn up into the glass barrel. Draw up just sufficient to 
float the hydrometer off the rubber packing in the bottom of 
the glass barrel. This type and arrangement is most com¬ 
monly used on account of the greater convenience in handling 
and on account of being able to make the readings more 
rapidly with less liability of spilling acid 
or getting it on the hands. 

To prevent the hydrometer from stick¬ 
ing to the side of the barrel, it is necessary 
that it be held in a vertical position. As 
some cells in some makes of cars are so 
situated that the hydrometer cannot be 
held in a vertical position while the nozzle 
is still held in the vent hole of the cell, the 
soft rubber plug in the bottom of the glass 
barrel is arranged in the form of a trap, 
so that, when sufficient acid has been 
drawn into the barrel, the hydrometer 
nozzle can be removed from the vent hole 
and held in a vertical position, and the 
acid will not run out while the reading is 
being taken. 

In recording the gravity of the dif¬ 
ferent cells, it is customary to number the 
cells consecutively, beginning with the 
positive cell in the front compartment of 
the car and following the cells in the order 
of the electric circuit. If the trays are to 
be removed from the car, the same order 
of cells can be maintained by numbering 
them in the same order; that is, begin¬ 
ning with the positive tray in the front compartment of the 
car, mark it No. 1, and so on through the entire battery, fol¬ 
lowing the electric circuit. 

As soon as sufficient electrolyte has been drawn into the 
glass barrel to float the hydrometer, care being taken that it 
does not stick to the sides of the barrel, note underneath the 
level of the electrolyte the graduation on the stem of the 
hydrometer. Reading the hydrometer by looking underneath 

9 



Fig. 3 

Type V-l Hydrometer 
Syringe, Complete 


Type V-l 
and Its Use 



















Manual of “jEXlDe” Batteries in Electric Vehicles 


the level of the liquid is usually more accurate than readings 
taken by observing above the level. 

By having a gravity record form tacked to a suitable 
board and placed on the fender of the car, one person can 
easily take the gravity readings with the left hand and note 
the readings on the form with the right hand, and in this way 
avoid getting any acid on the record form. 

When the readings have been taken and recorded, be 
careful to put the acid back into the same cell from which it 
was taken. Failure to do this often leads to trouble. That 
is, acid is often taken out of one cell, the gravity noted and 
the acid put back into another cell. The result is that the 
amount of acid taken out of the first cell is eventually replaced 
with water, leaving the electrolyte weaker; whereas the acid 
which was taken out and put into the other cell would make 
the electrolyte of that cell stronger, resulting in an irregular¬ 
ity in the different cells. 

As the battery is discharged the gravity of the electrolyte 
becomes less on account of a portion of the sulphuric acid 
contained in the electrolyte being used up in the plates in 
producing the current. In this way, during the normal dis¬ 
charge, the gravity drops about 100 to 150 points, depending 
on the type of the cell. So that, by noting the gravity of the 
electrolyte at any time and comparing it with the gravity at 
full charge, the state of charge at any time can be approxi¬ 
mately determined. 

As explained under “Electrolyte,” while the gravity of 
an electrolyte depends principally on the proportions of 
sulphuric acid and water of which it is composed, another 
condition also affects the specific gravity slightly, and that 
is temperature. The gravity of the electrolyte is assumed 
to be correct when the readings are taken at a temperature 
of 70 F. The gravity becomes one point heavier for each 
three degrees below 70°; also one point lighter for each three 
degrees above 70°. 

For the convenience of the operator, a thermometer has 
been designed with a special scale on the opposite side of the 
mercury column and parallel to the regular scale on which 
the amount of correction is indicated. That is, opposite to 

10 



The Hydrometer and Its Use 



Fig. 4. Thermometer Scale, Showing Temperature Corrections 


the temperature 70° is figure 0, showing that no correction is 
made at that temperature. Three degrees below 70° is shown 
minus 1, indicating that that gravity should be corrected 

11 











































































































Manual of “JExiOe” Batteries in Electric Vehicles 


at that temperature by deducting one point. Three degrees 
above 70° is shown plus 1, which indicates that the gravity 
at that temperature should be corrected by adding one point 
to the reading, as shown by the hydrometer. A sketch of 
this thermometer is shown in Fig. 4. 

When recording the gravity, do not make the correction 
for temperature, simply write down the hydrometer reading 
and the temperature, so that later, if it is desired to correct 
for temperature, it can be done. 






What is Meant by “Sulphated ” 


During any discharge of a battery, there is being formed 
sulphate of lead, without which there would be no production 
of current. If, however, charging is neglected, the sulphate 
reaches a condition which tends to fill the pores of the plates 
and make the active material dense and hard. It is this 
condition which is ordinarily referred to as “sulphated.” 

The cause of this condition is some form of abuse, such 
as: standing discharged for some length of time; habitual 
undercharging; neglecting evidence of trouble in individual 
cells; replacing evaporation with electrolyte, thereby restor¬ 
ing the specific gravity by adding acid to the cell instead of 
bringing it out of the plates by proper charging. 

The lead sulphate formed in a normal discharge of a 
battery is in a form in which it absorbs the charge very readily. 
When a battery is “sulphated,” as ordinarily expressed, the 
sulphate is then in a condition to absorb the charge with diffi¬ 
culty and the ordinary charge is insufficient. Continued and 
persistent charging at a low rate will restore any condition of 
sulphate, the time being in proportion to the degree to which 
the condition has been allowed to extend. It is a question of 
time, since a higher rate will only produce gassing and high 
temperature, the low rate being all which the battery in this 
condition is capable of using. 

The additional length of time to restore a “sulphated” 
battery is illustrated by the following test: A battery was 
charged to a maximum and the gravity regulated to exactly 
1.275 with the electrolyte just Yz inch above the top of 
the plates, this height being carefully marked. The battery 
was discharged and then recharged to 1.275 at the normal 
rates. The specific gravity changed from 1.265 to 1.275 dur¬ 
ing the last hour and a half of the charge. During the follow¬ 
ing twelve weeks, the battery was discharged and recharged 
daily, each charge being only to 1.265, thus leaving 10 points 
of acid still in the plates. At the expiration of the twelve 
weeks, the charge was continued to determine the time required 
to regain the 10 points and thus restore the specific gravity to 
the original 1.275. Eleven hours were required instead of the 
hour and a half first needed. The test further illustrates why 

1 


Formation of 
Sulphate 


Cause of 
Sulphate 


Normal 

Sulphate 

Abnormal 

Sulphate 

Decomposi¬ 
tion of 
Sulphate 


Illustration 







Manual.of “HxiDe" Batteries in Electric Vehicles 


a battery is given an overcharge to prevent its becoming 
“suiphated,” since, had the battery been charged daily to its 
maximum of 1.275 and discharged the same amount, as during 
the twelve weeks, nine and one-half hours of the last charge 
would have been saved. It is neither necessary nor desirable, 
however, to continue each charge to its maximum. The 
weekly equalizing charge is good practice. 


2 



Restoring a “Sulphated” Battery 

The user is frequently too ready to conclude that his 
battery is “sulphated” every time the mileage obtainable is 
not fully up to his expectations. 

If the sediment in a battery has not been allowed to reach 
the bottom of the plates and the level of the electrolyte has 
been properly maintained by replacing evaporation with pure 
water, the battery can be “sulphated” only because it has not 
been properly charged or because acid has been added to the 
electrolyte. An individual cell may become “sulphated” by 
an internal short circuit or by drying out as might be caused by 
failure to replace evaporation with water or failure to promptly 
replace a broken jar. 

To determine whether a battery is “sulphated,” when it is 
known that it does not need cleaning, it is advisable to remove 
it from the car, give it the ordinary equalizing charge and 
discharge it at the normal rate. If it gives its rated capacity, 
the reason for short mileage should be looked for elsewhere 
than in the battery. 

If the rated capacity is not obtained, recharge the battery 
in the regular way. When the battery is considered fully 
charged, take and record a hydrometer reading of each cell, 
and the temperature of one cell. A convenient form for this 
purpose is shown on page 6. Charge the battery at a rate 
as near one-half its normal “finishing” rate as the charging 
apparatus will permit. If the temperature reaches 110° F., 
reduce the current or temporarily interrupt the charge so as 
not to exceed this temperature. 

A battery is “sulphated” only when acid is tied up in the 
plates. When the specific gravity of the electrolyte has 
reached a maximum, it shows that there is no more sulphate 
to be acted upon, since during charging the electrolyte receives 
acid from no other source. Hydrometer readings should be 
recorded at regular intervals sufficiently frequently (say four to 
six hours apart) to determine if the specific gravity is rising or 
if it has reached its maximum. Continue the charge, record¬ 
ing the readings until there has been no further rise in any 
cell during a period of at least twelve hours. Maintain the 
level of the electrolyte at a constant height by adding water 

3 


General 


Test for 

“Sulphated” 

Condition 

If Rated 
Capacity 
is Obtained 

If Rated 
Capacity is 
not Obtained 

Treatment for 
Restoring a 
“Sulphated” 
Condition 










Manual of 44 lExtdC ” 


Batteries in Electric Vehicles 


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Manual of “JExtOc” 


Batteries in Electric Vehicles 


NAME 


ADDRESS 


191 


TYP E OF 5ATTERY 
BATTERY NO. 


G0N515T5 OF 


CELLS OF 


PLATES. NEW 


CAR NO. 


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Restoring a “ Sulphated ” Battery 


after each reading. (If water were added just before taking 
hydrometer readings, the water would not have time to mix 
with the electrolyte.) Hydrometer readings should be cor¬ 
rected for any considerable change in temperature in accord¬ 
ance with the scale shown on page 8. Should the gravity 
rise above 1.300 in any cell, draw off its electrolyte down to 
the top of the plates and put in as much water as possible 
without overflowing. Continue the charge, and if the gravity 
again goes above 1.300, it shows that acid had been added 
during the previous operation of the battery, and the elec¬ 
trolyte should be emptied out, replaced with water and the 
charge continued. 

The treatment can be considered complete only when 
there has been no rise in the gravity of any cell during a period 
of at least twelve hours of continuous charging. 

Upon completion of the treatment, the specific gravity of 
the electrolyte should be adjusted to its proper value of 1.270 
to 1.280, using water or 1.300 acid, as may be necessary. 

In cases where one or more individual cells have become 
“sulphated” while the balance of the battery is in good con¬ 
dition, it is better to remove such cells and treat separately. 

The active material of “sulphated” negative plates is 
generally of light color, and either hard and dense or granular 
and gritty and easily disintegrated. It is the negative plates 
which require the prolonged charge necessary to restore a 
“sulphated” battery. 

“Sulphated” positives, unless physically disintegrated or 
badly buckled, are but little changed in general appearance 
and can be restored to operative conditions, although their 
life will not be as great as if they had not been subjected to 
this abuse. 

“Sulphated” plates should be handled as little as possible. 

By following the few simple miles of operation, all the trouble, 
tune and expense of restoring a “ sulphated" battery can always 
be avoided. 


Treatment 

Completed 


Treating 

Individv 

Cells 


Appearance 

“Sulphated 

Plates 









Manual of ‘‘lExi^C” Batteries in Electric Vehicles 


















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Cleaning a Battery 

During the normal use of a battery the gradual wear of 
the plates results in a deposit (sediment) which collects in the 
bottom of the jar where a space is provided to hold a consider¬ 
able quantity before it accumulates sufficiently to touch the 
bottom of the plates. 

The rate at which sediment accumulates depends largely 
on whether the battery is charged properly. If the battery is 
charged in such a way as to cause excessive gassing, the gas 
coming out of the pores of the positive plates tends to soften 
and dislodge material; this is the reason the charging cur¬ 
rent is reduced whenever the cells begin to gas freely—to 
avoid excessive wear. If a battery habitually receives 
insufficient charging the sulphate which is thus allowed to 
accumulate in the negative plates will eventually lose its 
cohesion and the surface will gradually wash away and 
deposit in the bottom of the jar in the form of sediment. It 
is neither necessary nor desirable that each charge be carried 
to completion, but in order to make sure that the battery does 
not become “sulphated” the weekly equalizing charge is 
given. 

If a battery has been neglected and not cleaned until after 
the sediment has actually reached the plates, the sediment is 
then deposited much more rapidly and permanent injury to 
the plates and decreased life results. 

Since the conditions under which batteries are operated 
vary so widely, the best method of determining when it will be 
necessary to clean a battery is to remove the element from one 
cell after about 100 or 150 charges to determine the rate at 
which the sediment is accumulating. From the amount of the 
sediment compared with the space in the bottom of the jar. it 
is possible to estimate about when cleaning will be required. 
Always clean a battery before the sediment reaches the bottom of 
the plates. To insure this, do not count upon all the space, but 
allow Yz inch in making the above estimate. 

At the expiration of the estimated time, cut out a differ¬ 
ent cell to determine definitely if the time for cleaning has 
arrived. 

1 


Sediment 


Rate at which 

Sediment 

Accumulates 


When to Clean 


A 






Manual of “jSxlfte” Batteries in Electric Vehicles 


‘ Pillar strap connectors” or “cell connectors” 


When used to connect cells 
placed side by side is 
called a “side connector” 


When u:ed to connect cells 
placed end to end is called 
an end connector” 



Soft rubber plug 

Strap used to connect plates 
of a group 

Hold-down used to keep 
wood separators from 
floating 


Positive plate of a dark 
brown color 

Perforated rubber separator 
placed next to positive 

plate 

Grooved wood separator 
placed with smooth side 
next to negative piate 


Negative plate of a gray or 
slate color. 


Hard rubber jar 

The positive plates, when 
burned to the strap, as 
shown, are called the 
‘positive group” 

The negative plates, when 
burned to the strap, as 
shown, are called the 
negative group” 

Both groups and separators, 
assembled as shown, are 
called the “element” 

Rib or bridge for support- ■ 
ing the element 

Sediment space 






Fig. 1. 


One 9-MV “ Extbc ” 


Cell, Showing Parts Used and Method of Assembly 


2 



























Cleaning a Battery 


The method of procedure will depend upon the condition 
of the battery, as follows: 

1. If the battery has not been allowed to become “sul¬ 
phated” and the sediment has not reached the bottom of the 
plates, its cleaning is a comparatively simple operation and the 
only preliminary treatment is to first bring it to a state of full 
charge. 

2. If the battery is in a “sulphated” condition due to 
improper charging, but the sediment has not reached the bot¬ 
tom of the plates, it should be given the treatment, “ How to 
Restore a ‘ Sulphated ’ Battery ,” before cleaning. 

3. If the sediment has been allowed to reach the bottom 
of the plates because cleaning was not done soon enough, the 
battery will, as a matter of course, be in a “sulphated” con¬ 
dition by reason of the short circuits through the sediment. 
Such a battery must first be cleaned as described below and 
afterward given the treatment, “ How to Restore a ‘Sulphated’ 
Battery .” This treatment cannot be successfully given the 
battery in its short circuited condition. 

Before starting the work of cleaning a battery, have on 
hand a set of new wood separators and sufficient new acid of 
1.300 specific gravity from which to mix electrolyte. The 
amount of acid for different sizes and types of cells will be 
found on pages 4 and 5. The separator type and number can 
be found on the same page, but it is always well to specify the 
type of battery when ordering separators. Many of the old 
rubber separators can be used again, but it is well to provide 
about 25 per cent, of new ones. Order three or four extra 
rubber jars and covers. Examine the old trays to see if they 
are in sufficiently good condition to last the life of the plates. 
In ordering new trays, make a sketch (Fig. 2) showing the 
inside and outside length, width and height, and whether the 
sides are solid or slatted; also specify the size and type of 
handles and their position. 

Make another sketch (Fig. 3) showing both the position 
and polarity of the cells in each tray, and indicating the posi¬ 
tion of the terminals and their polarity; that is, whether the 
positive is to the.right or left side of the tray when facing the 
terminal end. 


How to Pro¬ 
ceed when: 

1. Battery 
not “Sul¬ 
phated” and 
Sediment not 
Touching 
Plates 

2. Battery 
“Sulphated” 
and Sediment 
not Touching 
Plates 


3. Sediment 

Touching 

Plates 


Ordering New 
Material 


3 









Manual of “jExtCe” Batteries in Electric Vehicles 


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General Specifications for Different Sizes and Types of Cells 
























































































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General Specifications for Different Sizes and Types of Cells 










































































































































Manual of “lExi^C” 


Batteries in Electric Vehicles 


Dismantling 

Battery 


To clean a battery, proceed as follows: 

Remove all of the connectors from the battery. This 
can be done by using the regular connector puller made for 



the purpose, or by drilling the connectors centrally in the top 
of the enlarged ends. A % inch wood bit is suitable (Fig. 4). 
After removing the connectors, remove all the covers by run¬ 
ning a hot putty knife around the sealed edges. After remov- 



£.S.B CO. 763 


Fig. 3. Layout of Cells in Tray 


6 


































Cleaning a Battery 


ing the covers, clean off the compound and place them in hot 
water. This will clean the acid from the covers and also 
soften them. In this condition, stack the covers and put a 
weight on top of them, to press them out flat. 

Lift all of the cells out of the trays, leaving the elements 
in their jars with the electrolyte. Examine the trays carefully, 


Part of connector cut away Cell to be Method of drilling 

to show depth of drilling removed connector 



Fig. 4. Drilling off Connectors 

and if they can be used again immerse them in a barrel of 
water in which has been dissolved about 10 pounds of bicarbon¬ 
ate of soda (common baking soda), to neutralize the acid in 
the trays. After drying, they will be ready for use. 

Grip one jar firmly between the feet, grasp the posts with 
pliers and lift out the element (Fig. 5). Spread the plates 
slightly and remove the wood and rubber separators, taking 
care not to injure the rubber sheets (Fig. 6). Separate the 
positive group from the negative. If the active material of 
the negative plates is swollen beyond the surface of the grid, 

7 











Manual of Batteries in Electric Vehicles 


Pressing 

Negative 

Plates 


Positive 

Plates 


press it back into position before it has a chance to dry, by 
placing boards of suitable thickness between the plates and 
carefully squeezing the group between heavy boards in a vise 



Fig. 5. Lifting Element out of Jar with Pliers 

or press. Use boards of sufficient size and thickness between 
the plates or breakage will result (Fig. 7). 

Charged negative plates when exposed to the air will in a 
short time become hot, and in this event should be allowed to 
cool before reassembling. 

Remove any loose particles adhering to the positive 
plates_by passing a smooth paddle over the surface; but do not 
wash the positive plates. 


8 












Cleaning a Battery 



Fig. 6. Removing Old Separators from Elements 



Fig. 7. Fressing Negative Group 

9 


A 






















Manual of “ Hxifte ” Batteries in Electric Vehicles 


Wash all sediment out of the jar to have it ready for re¬ 
assembling the element. Wash and save the rubber sheets; 
throw away the old wood separators. 

Reassemble the positive and negative groups with the 
Reassembling plates on edge, in order to insert the separators. Place a rub- 
Battery b er separator against the grooved side of a wood separator 
(Fig. 8) and insert between a positive and a negative plate 



E. S. B. Co. 755 

Fig. 8. Wood and Rubber Separator 


near the center of the element. The rubber sheet must be 
against the positive and the smooth side of the wood separator 
against the negative plate. In like manner, insert separators 
in all the spaces, working in both directions from the center. 
A separator left out means a short circuited cell. The separators 
should be practically flush with the bottom of the plates to 

10 


























































































































































































































































































































Cleaning a Battery 


bring their tops against the hold-down below the strap and 
must extend to or beyond the side edges of the plates (Fig. 9). 



Fig. 9. Installing Separators 


Grip the element near the bottom in order to keep the 
plates from flaring out while placing in the jar (Fig. 10). 

Fill the cell to within inch of the top of the jar, using 
electrolyte of a specific gravity of 1.250, unless battery is in 
a “sulphated” condition, in which case use water instead. 

After all of the cells have been reassembled, place them 
in trays in proper position, so that the positive of each will he 
connected to the negative of the adjoining cell and connect 
temporarily by pressing the old connectors in position. 

Put the battery on charge (Fig. 11) at the regular “finish¬ 
ing” rate. After charging about fifteen minutes, note the Charging 
voltage of each cell, recording these readings as shown in the 
first column of the form on page 19. 

This is to insure that all the cells have been connected in 
the right direction as to polarity. If they are properly con¬ 
nected, each cell should read above 2 volts. Any cell below 2 
volts is probably connected backwards; inspect it. 

When the cells begin to gas freely and uniformly, take and 
record a hydrometer reading of each cell and the temperature 

11 




































Manual of “JSxifce” Batteries in Electric Vehicles 



Fig. 10. Installing Element in Jar 

of one cell. Reduce the current to as near one-half the normal 
“finishing” rate of the battery as the charging apparatus will 
permit. 

Should the temperature at any time reach 110° F., reduce 
the current or temporarily interrupt the charge, so as not to 
exceed this temperature. 

Hydrometer and temperature readings should be recorded 
at regular intervals, sufficiently frequently (say four to six 
. Recording hours apart) to determine if the specific gravity is rising or if 
Readings ^ as reac h e d its maximum. Continue the charge, record¬ 
ing the readings, until there has been no further rise in any 
cell during a period of at least twelve hours. 

Maintain the level of the electrolyte at a constant height 
Replacing by adding water after each reading. (If water were added just 
Evaporation before taking hydrometer readings, the water would not have 
time to mix with the electrolyte.) 

12 










Cleaning a Battery 


Hydrometer readings should be corrected for any con¬ 
siderable change in temperature in accordance with the scale 
shown in Fig. 12. 

Should the gravity rise above 1.300 in any cell, draw off 
its electrolyte down to the top of the plates and put in as much 
water as possible without overflowing. Continue the charge, 



Fig. 11. Sketch of Connections for Charging Cells out of Vehicle 


and if the gravity again goes above 1.300, all the electrolyte in 
such cell or cells should be emptied out, replaced with water 
and the charge continued. 

The charge can be considered complete only when there Completion 
has been no rise in the gravity of any cell during a period of at of Charge 
least twelve hours of continuous charging. 

Upon completion of the charge, the specific gravity should 
be adjusted to its proper value (1.270 to 1.280) using water 

13 































































Manual of “lExiftC” Batteries in Electric Vehicles 


Adjusting 
Specific 
Gravity of 
Electrolyte 


or 1.300 acid, as may be necessary, and the electrolyte level 
adjusted to a uniform height of ]/z inch above the top of the 
plates. 



Fig. 12. Thermometer Scale, Showing Temperature Corrections. 


14 








































































































Cleaning a Battery 


Discharge the battery (Fig. 13 or Fig. 14) at its normal j es ( 
discharge rate (see page 5 or page 6), to determine whether Discharge 



Pig. lJ. Sketch of Connections for Discharging Cells through 

Regular Rheostat 


/f777/77<2 /e/' 



Fig. 14. Sketch of Connections for Discharging Cell through 

Water Rheostat 


15 


A 






















































































































Manual of ** lExiftC tf Batteries in Electric Vehicles 


Reburning 

Connectors 


there are any low cells caused by defective assembly, which 
should be immediately corrected. Recharge the battery and 
remove the temporary connectors. 

When the cells are arranged in their trays, as shown in 
the sketch made before the battery was taken apart, put the 
rubber covers in place, wipe the inside edges of the jars dry, 
and seal with the sealing compound supplied for this purpose. 

Heat the sealing compound, taking care that it is not 
allowed to burn, and apply around the edges of the cover, 
smoothing down with a hot putty knife. 

It is preferable to use new connectors, but if these have 
not been provided and if the old connectors have been removed 
with sufficient care, they may be used. Before replacing the 
connectors, see that the posts are scraped clean and smooth, 
in using oid connectors, clean the inside of the eyes of the 
connectors with a knife blade. When the connectors have 
been placed in position, tap them down firmly over the post to 
insure good contact. 

Before reburning the connectors, test each cell with a low 
reading-voltmeter to make sure that the cells have been con¬ 
nected up in the right polarity. It is not enough to note that 
the voltage is right in amount, but it must be determined that 
the polarity is in the right direction. 

Complete the connection by melting the lead of the con¬ 
nector and the post at the top so that they will run together, 
and while the lead is still molten, melt in more until the eye of 
the connector is filled. This is called “lead burning,” and can 
best be accomplished by means of a regular hydrogen flame, 
which should always be provided before attempting to do any 
work of this kind. 

Never use soldering flux of any kind. 

In lead burning, use only lead or alloy, similar to that of 
which the connectors are made. This can be procured in 
sticks (“burning strip”) or can be made by melting-down old 
connectors or plate straps. 

After all the connectors have been burned, connect the- 
trays together in the same way as they will be connected in 
the car. Charge at the regular finishing rate until all cells gas 
freely and uniformly immediately before installing the battery 
in the car, to insure that all cells are in good condition. 

16 








Cleaning a Battery 





Amperes per Positive Plate 


12 13 

ESB.Co.770 


17 







































































































































































































































































































































































































































































































































































































































































































































































































































































































































































Manual of “JEXt£>e” Batteries in Electric Vehicles 



14 15 16 

Amperes 



p, 18 19 20 21 22 23 

Positive Plate csb^s 


18 













































































































































































































































































































































































































































































































































































































































































































































































































































































Manual of “ j£xiC'C ,t Batteries in Electric Vehicles 


The cleaning of a battery which has been properly charged 
and in which the sediment has not been allowed to reach the 
plates is a simple operation compared with the treatment 
necessary to clean and restore a battery which has been 
neglected. 

Jt is of the utmost importance that a battery be cleaned before 
the sediment reaches the bottom of the plates . 


Conet Form 373 R Z— 12-13—25 M 

DATF. 3- tf'tf “E.XtOc” BATTERY REPORT No . / 


0 & Exide Depot 

No. CELLS -y-O TYPE // W1/ 

CHARGE STARTED 7:30 Y 191 Y_ENDED_ O J a ‘ ^ <9* ^ 


CELL 

NUM¬ 

BERS 

FIRST 

VOLTAGE 



srcc. giav. 

End of 

Charge 

VCLTAGE 

End of 

Charge 

SPEC. GRAV. 
after evening 
Electrolyte 

CELL 

NUM¬ 

BERS 

FIRST 

VOLTAGE 



SrtC GKAV 

End of 

Charge 

VOLTAGE 

End of 

Charge 

SPEC. GRAV. 
after evening 
Electrolyte 

1 

2 oS 



13 SS 

2 S'? 

/37t 

25 

2.34 



/2 7S 

2.St 

/ 3-7S 

o 

2 .2 6 



/3tY 

2 S' 

/ 2 7 t 

26 

2 04 



/X 7/ 

3 S8 

/27 4 

3 

2.oo 



/ 2 t 2 

2 S D 

/ X7 7 

27 

H 2 o *t 



j/rir 

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2 7 3 

4 

±o f 



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3 St 

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28 

1 oY 



. 7 7 ° 

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/i 73 

i 

2 / / 



/ X7 / 

X 6 O 

/ 2. 7Y 

29 

3 - Ot 



/3-7i~ 

2-So 

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6 

2/ C 



/3 £9 

2 6 . > 

L2- 7 3 

.30 

? ■ o 6 



/ 3 7 3 

2 S3 

737* 

7 

2/6 



/ 2-7 o 

2 S9 

/ 2 7 3 

31 

2/6 



/X77 

X S<t 

37 i 

S 

3 /V 



/ 7-73 

2 St 

/ 3 7 S 

32 

2 / 7 



/ X7¥ 

2 SI 

'3-7 S~ 

0 

2 /6 



/2 76 

a. st 

/ 2 7 V 

33 

3 / C 



/Z 7 3 

2 60 

/ % 7 V 

10 

2. /t 



'17 3 

3. So 

/ 2- 7 4 

34 

2/S 



73 fj. 

2 S' 

L 2? t 

11 

•J.-/S 



/ 2 7 7 

2.S7 

/ 3-7 £ 

35 

2 'S 



7~S7V 

2 St 

/ x TaT 

i 2 

2 / t 



/J7V 

2 S? 

/ 2 7 S’ 

36 

2 oo 



7 27 0 

2 60 

/ X7 3 

13 

2/o 



/ 2 y o 

2 

/ X 7 7 

37 

2/0 



JSTT 

3- S? 

! 2 7~T 

11 

2 20 



12 / 3 

2 s7 

/ 2 7 / 

33 

2 /« 



/ 2 7*/ 

2. S 9 

/ 2 7d~ 

15 

2 -3 £ 



/ 3 7£ 

2 £ o 

. Z 7S 

39 

2 07 



7 X to 

2 - 6 / 

' 2-/7° 

i-; 

2./ 6 



/ 2 7 3 

2 Tf 

/ Z 7^ 

10 

2 0 S’ 



/2-9/ 

2 )t 


17 

2/6 



13 to 

3 S' 

/ 2 7 X 

11 







13 

1 76 



3. 7Y 

s.s-9 

/ 2- 7 S' 

12 







19 

2. /// 



/ 29 0 

a st 

■220 

1 







20 

2 o < 



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a.s? 

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X 6o 

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2.o4 



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47 







21 

2 / t> 



72-79 

t-s° 

3- 7~S- 

48 








Pilot cell to be inside cell near center of buttery. Specific gravity readings taken every s.x (<i) hours at proper hour In first column and to contiuoe into 
following columns to end of charge. ., 

Electrolyte in pilot cell to be kept at uniform height at one-half inch above plates by addition of distilled water only. Water to be added juat after taking 
readings. . 

Any additional readings wanted can be put in blank columns, proper headings being filled »n. 

This sheet must be COMPLETELY FILLED OCT. no-.hmg u«ked for being imi’lcd. 

Discharge following this charge to be recorded on back of this sheet. 

S"oo _ )l. J 3 _,9i ■/- 


BATTERY FILLED WITH / 2 ° & 

BATTERY 

Pilot Cell No. /£ 


FROM 


. Sp. Gr. 

7:1* 


A. I P 1.V ’ T i-1 //Jje 


/<%«. J _ 



REMARKS: "■* 7tfl - /to 


ESBCo 773 


Specimen Form for Charging Record. Form 373 R 

19 


113 H—4-’14—3500 


































































































































































































. 









Batteries in Storage 

There are two general methods of putting a battery into 
storage, one known as “wet storage” and the other as “dry 
storage,” the method adopted depending upon the condition General 
ol the battery and the length of time the battery is to be out 
of commission, thus: 

WET STORAGE— 

Any battery out of commission for less than a year, 
providing it will not soon require repairs necessitat¬ 
ing dismantling. 

DRY STORAGE— 

(1) Any battery out of commission for longer than 
a year, no matter what its condition. 

(2) Any battery on which repairs necessitating 
dismantling are, or soon will be, required. 

Examine the condition of the plates and separators and 
also the amount of sediment in the bottom of the jars. If 
it is found there is very little sediment, and the plates and 
separators are in sufficiently good condition to give consider¬ 
able additional service, the battery may be put into wet 
storage by giving it an equalizing charge and storing away Wet Storage 
where it will be free from dust. Replace evaporation period¬ 
ically by adding distilled or other pure water to maintain the 
level of the electrolyte about Yz inch above the top of the plates. 

At least once every four months charge the battery at one-half 
the normal “finishing” rate until all the cells have gassed con¬ 
tinuously for a period of at least three hours. Any cells not 
gassing should be examined and the trouble remedied. 

When the examination has shown that the battery will 
soon require cleaning or repairs, it should be put into dry Dry Storage 
storage in a place free from dust, proceeding as follows: 

Make a sketch (Fig. 1) showing the position and polarity 
of the cells in each tray, and indicating the position of the Sketch of 
terminals and their polarity; that is, whether the positive is to Battery 
the right or left side of the tray when facing the terminal end. 

Remove all of the connectors from the battery. This can Dismantling 
be done by using the regular connector puller made for the Battery 

1 








Manual of "JSxtDc’' Batteries in Electric Vehicles 


■j= 




— 4 — 

T 




/ 


£S0.CO.763 

Fig. 1. Layout of Cells in Tray 


purpose, or by drilling the connectors centrally in the top of the 
enlarged ends. A inch wood bit is suitable (Fig. 2). After 
removing the connectors, remove all the covers by running a 
hot putty knife around the sealed edges. After removing the 
covers, clean off the compound and place the covers in hot 

Part of connector cut away Cell to be Method of drilling 

to show depth of drilling removed connector 



Fig. 2. Drilling off^Connectors 
2 




























Batteries in Storage 


water. This will clean the acid from the covers and also soften 
them. In this condition, stack the covers and put a weight 
on top of them, to press them out flat, and store them away. 

Lift all of the cells out of the trays, leaving the elements 
in their jars with the electrolyte. Examine the trays care¬ 
fully, and if they can be used again, immerse them in a barrel 
of water in which has been dissolved about 10 pounds of 
bicarbonate of soda (common baking soda) to neutralize the 
acid in the trays. After drying, store them away. 

Grip one jar firmly between the feet and with pliers grasp 
the posts and lift out the element (Fig. 3). 



Fig. 3. Lifting Element out of Jar with Pliers 

3 


















Manual of “ lExtfce ” Batteries in Electric Vehicles 


Spread the plates slightly and remove the wood and rub¬ 
ber separators, taking care not to injure the rubber sheets 
(Fig. 4). 



Fig- 4. Removing Old Separators from Elements 

Separate the positive group from the negative. If the 
active material of the negative plates is swollen beyond the 
surface of the grid, press it back into position before it has a 
chance to dry, by placing boards of suitable thickness between 
the plates and carefully squeezing the group between heavy 
boards in a vise or press. Use boards of sufficient size and 
thickness between the plates or breakage will result (Fig. 5). 

Charged negative plates when exposed to the air will in a 
short time become hot; they should be allowed to stand in the 
air until cooled. 

If the positive plates show much wear, they should be 
scrapped; if not, remove any loose particles adhering to them 
by passing a smooth paddle over the surface; but do not wash 
the positive plates. 

Empty the acid out of all of the jars into a glazed earthen¬ 
ware vessel or lead lined tank (save this acid for giving the 
negative plates their final treatment before storage), and wash 

4 













Batteries in Storage 


all sediment out of the jars. The rubber separators should be 
carefully washed, dried and tied in bundles. 

Place the positive groups together in pairs, put into jars 
and store away. 

Place the negative groups together in pairs, put into the 
remaining half of the jars, cover with acid saved for the pur- 



Fig. 5. Pressing Negative Group 

pose and allow to stand for at least five hours. Pour off and 
throw away the acid and store away the jars containing the 
negatives. 

Record the amount of material which will be required for 
reassembling the battery. When ordering the new material, 
provide three or four extra jars and covers in addition to those 
considered necessary for replacement, and about 25 per cent, 
extra rubber separators to take care of possible breakage in 
reassembling. Order new electrolyte of 1.200 specific gravity; 
the quantity required for cells of various sizes and types is 
shown in the tables on pages 6 and 7. Unless the old con- 

5 















Manual of “JEXifre” Batteries in Electric Vehicles 


a) 

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> 

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£ 

0 

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Manual of <4 l£xiftc" Batteries in Electric Vehicles 


nectors were very carefully removed, order new ones. A new 
set of wood separators with 10 per cent, excess should be pro¬ 
vided, but since wood separators must be kept wet, it is 
advisable not to order these too long in advance. 

When the work is being done for a customer, it is well to 
advise him at the beginning of the storage period of the amount 
Advising of material required and request him to give about a month’s 
Owner no tice in order to insure ample time to procure the new mate¬ 
rial, assemble and charge the battery. 

To reassemble the battery, proceed as when making a 
complete renewal of the elements, which is fully described 
under that heading. 




Form 1113 1—4-’14—3500 


8 









Complete Renewal of a Battery 

The following is a tabulated list of material required for 
making a complete renewal: 

Positive Groups or I ^ os[ M ve P Iates 

i Positive straps 

Negative Groups or [ Negative plates 
^ l Negative straps 

Connectors 
Burning Strip 
Wood Separators 
Rubber Separators 
Rubber Tars 
Rubber Covers 
Rubber Plugs 
Sealing Compound 
Electrolyte 
Trays 

Handles and Terminals 

Groups—Plates: Note the number of plates in each 
cell and their size and type; that is, whether they are 
“lExtftC” or etc. This information can usually 

be obtained from the name plate on each tray. 

Unless facilities are available for burning the plates into 
groups, it is better to order groups. If the plates are ordered 
loose, positive and negative straps should be included in the 
order. In any case the following information is required: 
Size and type of plate 
Number of plates per cell 
Length of jar outside 
Width of jar outside 
Height of jar outside 
Height from top of rib to top of jar 

Connectors: In ordering connectors, give the distance 
between the center of the eyes (Figs. 1 and 2), noting if more 
than one size is required. 

Terminal connectors are now all of one type, the only 
difference being in the size (Figs. 3, 4 and 5). Give the top 
diameter of the cell terminal post (see A, Fig. 11), the size of 
cable and length of cable for each terminal. 

Burning Strip: Two pounds of burning strip is suf¬ 
ficient for burning the connectors of an ordinary battery; when 
loose plates are ordered, provide 1 pound additional for each 
fifty plates. The clippings from the plate lugs can, if desired, 
be melted down and cast into strips for this purpose. 

1 


Material 

Required 


Manual of ** lEXtftC m Batteries in Electric Vehicles 



'Pillar strap connectors” or “cell connectors” 


When used to connect cells 
placed side by side is 
called a “side connector’ 


When used to connect cells 
placed end to end is called 
an “end connector” 


Soft rubber plug 

Strap used to connect plates 
of a group 

Hold-down used to keep 
wood separators from 
floating 


Positive plate of a dark 
brown color 

Perforated rubber separator 
placed next to positive 
plate 

Grooved wood separator 
placed with smooth side 
next to negative plate 


Negative plate of a gray or 
slate color. 


Hard rubber jar 


The positive plates, when 
burned to the strap, as 
shown, are called the 
“positive group” 

The negative plates, when 
burned to the strap, as 
shown, are called the 
“negative group” 

Both groups and separators, 
assembled as shown, are- 
called the “element” 


Rib or bridge for support¬ 
ing the element 

Sediment space 


One 9-MV “ Exi&c ” Cell, Showing Parts Used and Method of Assembly 


2 
























Complete Renewal of a Battery 


Wood Separators: The separator type number can be 
found in the accompanying tables (see pages 5 and 6). In 
ordering these, it is well to provide about 10 per cent, excess 
over those actually required. 

Rubber Separators: Most of the old rubber separators 
can be used again, but it is well to provide about 25 per cent, 
of new ones. 

Rubber Jars and Covers: Order three or four extra 
rubber jars and covers. Give outside dimensions of jars— 
length, width and height; and distance from top of rib to top 
of jar. 

Rubber Plugs: It is advisable to order a new set of 
plugs. 



Fig. 1. Connector, Showing Centers of Eyes 



E.S.BCO 623 

Fig. 2. Flexible Connector 


Sealing Compound: The average size pleasure car or 
light truck battery requires about ]/% pound of sealing com¬ 
pound per cell. The compound comes in 5, 10 and 30 pound 
tins. 

Electrolyte: Order as much 1.200 electrolyte as will be 
needed; the amount required for the different types and sizes 
of cells can be found on pages 5 and 6. As electrolyte is 
usually longer in transit than other material, this should be 
allowed for. 

Trays: In ordering new trays, make a sketch showing 
the inside and outside length, width and height (Fig. 9), and 
whether the sides are solid or slatted; also specify the size and 
type of handles and their position. The trays, when obtained 
locally, should be carefully painted with special acid resisting 
paint. 

Handles and Terminals: In ordering handles, state 
size and whether they are surface or flush type. If new 
terminals are required, specify type (Figs. 6, 7, 8). 

3 














Manual of “ H.XidC " Batteries in Electric Vehicles 


Upon receipt of the new material, give immediate atten¬ 
tion to the wood separators to prevent their drying out. 
Wood separators must be kept wet. 

When plates and straps are to be burned into groups, pro¬ 
ceed as follows: Scrape the plate lugs clean and bright and 




Fig. 6 






Fig. 3. Style H Terminal Connector 


Fig. 4. Style HH Terminal Connector 
Fig. 5. Style HHH Terminal Connector 
Fig. 6. Wing Nut Terminal 
Fig. 7. Box Type Terminal 
Fig. 8. Set Screw Terminal 




4 


















Complete Renewal of a Battery 


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neral Specifications for Different Sizes and Types of Cells 


































































































Complete Renewal of a Battery 


arrange the plates in a burning box as shown in Fig. 10. 
The height of this box should be y& of an inch less than 
the distance from top of the ribs of the rubber jar to the top 
of the jar. The burning iron, which acts as a spacer between 
the plates and as a support for the strap, should be made of 
iron Y% inch thick, slotted to fit the plate lugs. This }£ of an 



inch, in addition to the height of the burning box, will give the 
right height for the strap, the bottom of which should be y of 
an inch below the top of the jar. 

Place the strap over the plate lugs to rest on the burning 
iron. The plate lugs should be trimmed about flush with the 
top of the strap. After burning, cut off the projecting ends 
of the negative straps so that the elements may enter the jars 
(Fig. 11). It is not necessary to clip off the projecting ends of 
the positive straps. 

The old battery can now be dismantled, first making 
sketch, showing both position and polarity of the cells in each 
tray and indicating the position of the tray terminals and 

7 


Grouping 

Plates 


Dismantling 
Old Battery 






















Manual of “JSxide" Batteries in Electric Vehicles 



Fig. 10. Assembling Group in Burning Box 


A 




Fig. 11. Clipping off End of Negative Strap 

8 




























Complete Renewal of a Battery 


their polarity; that is, whether the positive is to the right or 
left side of the tray when facing the terminal end (Fig. 12). 




To dismantle a battery, proceed as follows: 

Remove all of the connectors from the battery. This can 
be done by using the regular connector puller made for the 
purpose or by drilling the connectors centrally in the top of 
the enlarged ends. A y$ inch wood bit is suitable (Fig. 13). 


Part of connector cut away Cell to be Method of drilling 

to show depth of drilling removed connector 







\ 

T 




1 


£ S.B.CO.763 


Fig. 12. Layout of Cells in Tray 


Fig. 13. Drilling off Connectors 

9 





















Manual of “lExifte” Batteries in Electric Vehicles 


After removing the connectors, remove all the covers by run¬ 
ning a hot putty knife around the sealed edges. After removing 
the covers, clean off the compound and place them in hot 
water. This will clean the acid from the covers and also 
soften them. In this condition, stack the covers and put a 
weight on top of them, to press them out flat. 

Lift all of the cells out of the trays. When making a 
complete renewal, the old trays are seldom worth saving; but 
if they are to be used again, immerse them in a barrel of water 
in which has been dissolved about 10 pounds of bicarbonate of 
soda (common baking soda), to neutralize t he acid in the trays. 
After drying, they will be ready for use. 



Fig. 14. Lifting Element out of Jar with Pliers 

10 


















Complete Renewal of a Battery 


Grip one jar firmly between the feet, grasp the posts with 
pliers and lift out the element (Fig. 14). 

Spread the plates slightly and remove the wood and 
rubber separators, taking care not to injure the rubber sheets 
(Fig. 15). 



Fig. 15. Removing Old Separators from Elements 

Throw away the old wood separators and scrap the old 
plates. Wash all sediment out of the jars to have them ready 
for assembling the new elements. 

Assemble the new positive and negative groups with the 
plates on edge in order to insert the separators. Place a rub¬ 
ber separator against the grooved side of a wood separator 
(Fig. 16) and insert between a positive and a negative plate 
near the center of the element. The rubber sheet must be 
against the positive and the smooth side of the wood sepa- ^ Elements 
rator against the negative plate (Fig. 17). In like manner, 
insert separators in all the spaces, working in both directions 
from the center.' A separator left out means a short circuited 
cell. The separators should be practically flush with the bot¬ 
tom of the plates to bring their tops against the hold-down 
below the strap, and must extend to or beyond the side 

11 




















Manual of 


“^ExiS'C” Batteries in 


Electric Vehicles 




Fig. 17. Installing Separators 
12 























































































































































































Complete Renewal of a Battery 


edges of the plates. Grip the element near the bottom in 
order to keep the plates from flaring out while placing in the 
jar (Fig. 18). 

Fill the cells to within l /z inch of the top of the jars, using 
electrolyte of a specific gravity of 1.200, and allow the cells to 
stand from twelve to twenty-four hours before starting to 
charge. 

After all the cells have been assembled, place them in 
trays in proper position, so that the positive of each will be con- 



Fig. 18. Installing Element in Jar 

nected, to the negative of the adjoining cell , and connect temporar¬ 
ily by pressing connectors into position, using the old ones if 
available. 

Give the “initial charge” as follows: 

Put the battery on charge at the regular finishing rate. „| ^ | 
After charging about thirty minutes, note the voltage of each Charge” 
cell, recording these readings as shown in the first column 

13 







Manual of 


Batteries in Electric Vehicles 


of the accompanying form (Fig. 19). This is to insure that 
all the cells have been connected in the right direction as to 
polarity. If they are properly connected, each cell should 
read above 2 volts. Any cell below 2 volts is probably con¬ 
nected backward; inspect it. 

Reduce the current to as near one-half the normal “fin¬ 
ishing” rate of the battery as the charging apparatus will per- 


Conat Form 173 R 3—12- - 13—2SM 


DA-rr “Exibc" BATTERY REPORT 

v L' Exide Depot 


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Pilot coll to lie inside cell near center of battery- Specific gravity readings taken every six hours at proper hour in rirst column and to conduce into 
following columns to end of charge. 

Electrolyte In pilot cell to be kept at uniform height nt one-half inch above plates l»y addition of distilled fitter only. Water to be added just after taking 
readings 


Any additional rending*: wanted can be put in blank column*, proper he adings In ing filled in. 
Thu6hcet must be COMPLETELY KILLED ot’T. no:hang asked for being >mi’ted. 
Difcharge following this charge 10 be recorded on back of this sheet. 


BATTERY FILLED WITH / 2 0 0 

BATTERY &Jc*dtsK2*4. 

Pilot Cell No. /£ 


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“TabGo 773 


Fig. 19. Specimen Form for Charging Record. Form 373 R 




















































































































































Complete Renewal of a Battery 


mit. Select one cell near the center of the battery, which will 
be the “pilot cell” throughout the entire charge. Record read¬ 
ings of time and current, and the specific gravity and temper¬ 
ature of the pilot cell, as indicated in the form, Fig. 19, at 
intervals of from six to twelve hours. Should the temperature 
at any time reach 110° F., reduce the current or temporarily 
interrupt the charge so as not to exceed this temperature. 

Maintain the level of the electrolyte by adding water as 
necessary. Never add water just before taking hydrometer 
readings, because it would not have time to mix with the 
electrolyte. Hydrometer readings should be corrected for any 
considerable change in temperature in accordance with the 
scale shown in Fig. 20. 

When the gravity of the pilot cell has shown no further 
rise during a period of twenty-four hours, record hydrometer 
readings of each cell in the columns marked “Spec. Grav.” 
(k ig. 19). In recording readings, start at the positive terminal 
cell of the battery as cell No. 1, and follow the direction of 
the electric circuit. Individual cell readings should be recorded 
at intervals of about twelve hours to insure that each reaches 
a maximum. Bear in mind that the object of the initial 
charge is to completely remove all acid combined in the plates. 

Do not stop the initial charge simply because a gravity of 
1.270 or 1.280 may have been reached, because this may not 
be the maximum. Continue to charge as long as the gravity 
continues to rise. The charge can be considered complete 
only when there has been no rise in the gravity of any cell during 
a period of twenty-four hours'of continuous charging. 

In case the gravity rises above 1.290 in any cell, draw off 
its electrolyte down to the top of the plates and replace with 
water, saving this electrolyte for adjusting the specific gravity 
of the cells as follows: 

Upon completion of the charge, adjust the specific gravity 
to its proper value (1.270 to 1.280), using water or electrolyte 
as may be required, and bring the level of the electrolyte to 
a uniform height of fz inch above the top of the plates. 
Some variation in the specific gravity among different cells is 


Completion of 

“Initial 

Charge” 


Adjusting 
Specific 
Gravity 
of Electrolyte 


15 




Manual of “Bxtfte” Batteries in Electric Vehicles 


Fig. 20. 










-+ 19 



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16 


f 









































































































































Time in Hours /5 minutes per division I Volts perCell 


Complete Renewal of a Battery 



Amperes per Positive Plate 


12 13 

LSB.Co.770 


17 















































































































































































































































































































































































































































































































































































































































































Manual of “JExiDc” Batteries in Electric Vehicles 



12 13 W 15 16 17 18 19 20 21 22 23 

Amperes per Positive Plate esecojea 

18 




















































































































































































































































































































































































































































































































































































































































































































































Complete Renewal of a Battery 


to be expected, since the amount of water in the separators 
difference in level when filled, etc., affect this. 



Sketch of Connections for Discharging Cells through Regular Rheostat 


/cr 


or Zones' <s s 

e/rc/ro o'os/o 

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4- e/cc/rofef/c// 
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£> s cfyu s/<a c/ 



C3B.Co.766 

Sketch of Connections for Discharging Cells through Water Rheostat 

19 


















































































































Manual of *‘ Bxifce ” Batteries in Electric Vehicles 


Test 

Discharge 


Warning 


Discharge the battery, preferably at its normal discharge 
rate (see pages 5 and 6), to find any possible low cells, caused 
by defective assembly, which should be immediately corrected, 
and to determine the capacity. A convenient form for keep¬ 
ing the discharge record is shown on page 21. 

Capacity does not necessarily indicate the completeness or 
incompleteness of the initial charge. The only sure indica¬ 
tion is maximum specific gravity reached in every cell. 

Should a second test discharge be taken, the capacity will 
be somewhat less than that of the first; but after several dis¬ 
charges, the battery will not only recover but will exceed its 
first capacity. 

The foregoing outline of procedure is based upon the 
assumption that the initial charge is continuous, since this 
will require the shortest time. It is especially desirable that 
at least the first twenty-four hours of the charge be given 
without interruption even if the entire charge cannot be made 
continuous. Where there are interruptions, the twenty-four 
hours of maximum gravity must be actual charging time and 
must not include any idle time. 

The accuracy of the ammeter should be checked at the 
currents used. 

A battery which has not received sufficient initial charge 
cannot be expected to give satisfactory service and life. 
Therefore, in case of any doubt, prolong the charge rather than 
run the chance of stopping it too soon. 

As a further precaution, it is advisable to see that the 
first few charges after the battery goes into service are some¬ 
what prolonged. 


20 








Complete Renewal of a Battery 


J 


date^« 117 -/ f/y DISCHARGE No . / 

fun -£. 2 : J . .Amperes Fon ■F'^T'houbs. Temperature Begirrino of Discharge 9 # Temperature Ero of Discharge 7 ? . 

- ./ . Discharoe Started /./.!? O .191..^ Enoco . 4 *' 4 ~iT -» " ■ Y 


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48 















First discharge voltage reading to be taken for *'Ex(hc” cella at end of three and one-half ( P-O hours for "HccapsExihc" cells at four and one-half (4^1 
hours: for •Tbln*Exlt>c" at five and one-half [b%) hours, and second reading twenty (JO) minutes after first reading, third reading twenty (20) minutes after second 
reading. Final reading when several ceils reach 1.7 volts, notlug total elapsed time. 

Additional readings may be recorded in blank columns, proper headings being filled in. 

If this is final discharge before shipment, make a note to this effect in the space provided for remarks. 


REMARKS: 


Specimen Form for Discharge Record. Form 373 R 


21 


Form 1113 J—4-’14—3500 































































































































































1 


Replacing Evaporation 

The electrolyte in a cell consists of a mixture of sul¬ 
phuric acid and water. Sulphuric acid does not evaporate, 
water does. When the level of the electrolyte in a cell be¬ 
comes low, it is due, under normal conditions, to the evapora¬ 
tion of water, which should be replaced with water only. 

There being no loss of acid, it is never necessary, during 
normal service, to add any acid to a battery. 

Of course, if a battery is upset and acid spilled or if a 
jar is broken and acid leaks out, it should be replaced. In the 
event of any cells having been flooded, by wash water or other 
cause, provision should immediately be made to prevent a 
recurrence Unless acid is actually known to be lost out of a 
cell , none should ever be added during the entire life of a battery. 
The amount of acid lost in spray is immeasurably small and 
should be neglected. 

Use only distilled or other water of approved purity for 
replacing evaporation. Most natural waters contain impuri¬ 
ties, some of which are chemically injurious to batteries, while 
others are not. Water for regular use in batteries should 
always be submitted to the battery manufacturer for approval. 

It is necessary that the plates and separators be covered 
with electrolyte at all times. When adding water, cover the 
plates about % inch. Do not put in more than this amount, 
as cells which are filled too full tend to slop over while the 
car is being run and also while charging, since the gassing 
raises the level of the electrolyte. 

Replace evaporation every five to fifteen days, depending 
upon the conditions of service. The best time for adding 
water is just before a charge. 

A good method of replacing evaporation is to use a syringe, 
a standard hydrometer syringe, with the hydrometer removed, 
being suitable. 

The electrolyte in a fully charged cell of the vehicle type 
should have a specific gravity of 1.270 to 1.280, although the 
battery will continue to give good service between the limits 
of 1.250 and 1.300. If the specific gravity of the electrolyte 
in any cell is higher than 1.300, it should be reduced; if lower 
than 1.250, the cause should be promptly investigated and 
corrected. 


General 

Why Use 
Water Only 

Never Add 
Acid 


Replacing 
Spilled Acid 


Kind of Water 
to Use 


Amount of 
Water to Use 


When to 
Replace 
Evaporation 

Good Method 
of Replacing 
Evaporation 


1 




Manual of Batteries in Electric Vehicles 


During discharge the gravity of the electrolyte becomes 
lower on account of a portion of the acid in the electrolyte 
being combined in the plates in producing the current. Thus, 
at the finish of a normal discharge the electrolyte is 100 to 150 
points lower than at the beginning. When the battery is 
recharged, the acid will be returned to the electrolyte and will 
restore it to the former gravity. 


* 


Form 1113K—4-'14—3500 



2 





























_ 


















































































* 
















































Adjusting the Specific Gravity of 

the Electrolyte 

The electrolyte of a fully charged cell of the vehicle type 
should, when first put into service, have a specific gravity of 
1.270 to 1.280; but although with age this gravity will change 
somewhat, the battery will continue to give good service 
between the limits of 1.250 and 1.300. If the gravity should 
ever rise above 1.300, it should be promptly lowered by replac¬ 
ing some of the electrolyte with water. Low gravity in a bat¬ 
tery or cell is usually caused by acid being combined in the 
plates through lack of charge, although if a battery is upset 
and acid spilled or if a jar is broken and acid leaks out, no 
amount of charging will restore the specific gravity. In the 
event of any cells having been flooded, by wash water or 
other causes, provision should immediately be made to prevent 
a recurrence. Decreasing gravity throughout the battery 
{when not due to insufficient charging) indicates that sediment 
is accumulating in the bottom of the jars. 

Before attempting to raise the gravity of any cell by 
adding acid, always charge the battery until sure that a maxi¬ 
mum gravity has been reached; or in other words, that no acid 
remains combined in the plates. For example, if the electro¬ 
lyte in a cell should be adjusted to 1.275 when 50 points of 
acid remained in the plates, the gravity would come up to 
1.325 if the cell were afterward charged to its maximum. 

To adjust the specific gravity to its proper value (1.270 
to 1.280), first bring the battery to its true maximum, which 
can only be assured by charging until there is no further rise 
in gravity during a period of at least twenty-four hours of 
continuous charging at about one-half the normal “finishing” 
rate. Remove the electrolyte down to the top of the plates 
and replace with water or 1.300 electrolyte as required. 

When much adjustment is necessary and facilities are 
available, as in garages or large installations, it is good practice 
to pour the electrolyte out of the cells into a glazed earthen¬ 
ware vessel or lead lined tank, and raise or lower the gravity 
of this electrolyte as may be necessary. About one-third of 
the electrolyte is held in the plates and separators and cannot 

1 


Gravity 
too High 


Gravity 
too Low 


Charge to 
Maximum 
before 
Adjusting 


how to Adjust 



Manual of “lExi^C” Batteries in Electric Vehicles 


be poured out, and this should be allowed for in estimating the 
proper gravity before refilling the cells. 

In cases where there was a wide variation between differ¬ 
ent cells, further adjustment may be necessary. 

Never Unless acid is actually known to be lost out of a cell, none 
Add Acid should ever be added during the entire life of a battery. The 
amount of acid lost in spray is immeasurably small and should 
be neglected. 






Shipping Water and Electrolyte 

1 

Sulphuric acid, when shipped by freight, is classified as 
dangerous and therefore must be marked with a label as shown 

in Fig. 1. 


NOTICE 

HANDLE CAREFULLY 

ACID 

DO NOT LOAD WITH EXPLOSIVES OR 
INFLAMMABLES PROTECTED 
BY YELLOW LABELS 

Shipper has certified on his Shipping' Order to 
compliance with all Regulations that 
apply to this package 


Fig. 1. White Label for Freight Shipments of Acids. (Reduced Size) 


These labels must be supplied by the shipper, although 
they may be obtained from local freight agents. On the bill 
of lading for all acid shipments, make the following notation: 

“This is to certify that the above articles are properly 
described by name, and are packed and marked, and are 
in proper condition for transportation, according to t e 
regulations prescribed by the Interstate Commerce Com- 

• • y y 

mission. 


3 






Manual of ‘ 4 JExiD C ” Batteries in Electric Vehicles 


The following is a copy of the requirements of the Inter¬ 
state Commerce Commission in this connection: 

“The American Railway Association 
REGULATIONS 
for the 

TRANSPORTATION OF INFLAMMABLE ARTICLES 

AND ACIDS 

Approved May 19, 1909; amended May 18, 1910 


GENERAL NOTICE 

Shippers’ certificates and labels are prescribed herein, 
to facilitate compliance with Section 235 of an Act of 
Congress, approved March 4, 1909, which required 
shippers of explosives and other dangerous articles 
to plainly mark the contents of each package and to 
inform the carrier of the true character thereof, and 
also to comply with the requirements of the Inter¬ 
state Commerce Commission’s Regulations for the 
Transportation of Explosives. 

Section 1853. Sulphuric or Hydrochloric Acids and 
Liquid Chlorides must be packed in earthen jars 
or glass bottles, or strong carboy bottles, without 
local defects, all well stoppered to prevent leakage, or 
in drums or tank cars. Jars or bottles must be 
packed in a strong case and well cushioned; carboy 
bottles must be packed in cases provided with strong 
handles or cleats, and the necks of carboys must be 
protected.” 

Acid will be accepted by the freight companies in glazed 
earthenware jugs, suitably packed, or in the regular carboys. 
When shipped in carboys, the neck of the carboy must be 
protected. 

Distilled water may be shipped by freight in any kind of 
vessel; but in order to distinguish it from acid, it should be 
marked as distilled water, which will enable it to be shipped 
with less difficulty. 

As distilled water is usually obtainable locally, there is 
seldom an occasion to ship it by freight. 

When sending by express samples of electrolyte for 
analysis, send at least one pint, and in order to comply with 
the Interstate Commerce regulations, this must be packed in 

4 







Shipping Water and Electrolyte 


bottles of strong glass or earthenware jugs of not to exceed 
5 gallons capacity and stoppered with ground glass or rubber 
stoppers, packed in strong wooden boxes cushioned with 
absorbent packing material in quantity sufficient to absorb 
and hold all of the liquid. 

On the outside of the package put the regulation caution 
label, which is a square white label as shown in Fig. 2. 

As it is so often desired to obtain analysis of acid and 
water for use in connection with storage batteries, this Com¬ 
pany has arranged to analyze, free of charge, any samples sent 
prepaid to us by customers for that purpose. For analysis of 
water, at least a quart is required; for acid, a pint is sufficient. 
Put a label on each bottle showing its contents and where it is 
from. Send the sample by express, prepaid, to The Electric 
Storage Battery Company, 19th Street and Allegheny Avenue, 
Philadelphia, Pa., and write a letter advising of the ship¬ 
ment and to whom the report of the analysis should be sent. 



DO NOT LOAD WITH EXPLOSIVES OR 
INFLAMMABLES PROTECTED 
BY YELLOW LABELS 

This is to certify that the above articles are properly 
described by name and are packed and marked 
and are in proper condition for transpor¬ 
tation, according to the regulations 
prescribed by the Interstate 
Commerce Commission 

(Shipper's Name) 


Fig. 2. White Label for Express Shipments of Acids and Corrosive 

Liquids. (Reduced Size) 


5 


Form 1113 L 




























How to Pack for Shipment 

The damage in transit to batteries returned for repairs 
has shown the necessity of using care in packing, and the 
following procedure is therefore recommended: 

1. Procure a strong box (see illustration) of 1 inch to 
1 x /i inch lumber and made with A shaped ends to prevent 
the package from being placed upside down. The inside ® ox 
dimensions should be at least 2 inches greater than the over 
all size of the trays to be packed, allowing in addition 2 inches 



between trays when more than one is to go in the box. If 
the trays are not too large, two, or even more, may be packed 
together, but if possible a weight of 200 pounds per package 
should not be exceeded. 

2. Cover the bottom of the box with a layer of excelsior, 
shavings or coarse sawdust at least 2 inches thick, and on Packing 
this place each tray of cells. Over the top of the cells place 

1 












Manual of “JEXtDc” Batteries in Electric Vehicles 

— 

paraffined paper, and then cover the whole tray with stout 
wrapping paper, folding it down over the sides of each tray 
to keep packing material and dust out of the cells. 

3. Fill the space around the sides and ends of trays with 
excelsior, coarse sawdust, shavings or even twisted and 
crumpled balls of paper, ramming down tightly. 

4. Leave the tops of the trays free of packing material 
and covered only with the paper. 

5. Nail slats on the box for a cover—never make a solid 
cover—and nail a stout strip on each side, extending beyond 
the ends, for handles. The slatted cover enables the freight 
handlers to see the contents of the package and helps toward 
careful handling. 

Labeling 6. Label the box “Handle with Care” and “ Do Not 
Drop.” 


General Suggestions 


Shipping Before making shipment, always write to the nearest 
Instructions Sales Office of the Company for shipping instructions. 

Number the packages and always mark each packing 
Marking case clearly with the name and address as given in the shipping 
Packages instructions. Do not address to Sales Office. Also mark with 
your own name as shipper, for identification upon arrival at 
destination. 

When sending bill of lading to the nearest Sales Office, 
advise them of the entire contents of each package. 

All freight is handled most expeditiously and carried at 
Bills of i eas t expense when bills of lading are made out correctly, and 
Lading shipment described according to the terms of the railroad 
freight classifications. 

Completely assembled batteries should be shipped as 
“Electric Batteries, N. O. S.” 


Note. —No railroad caution labels are required; the electrolyte 
is so dilute that it is specifically excepted from the label rules when 
contained in the cells of a battery. 


Miscellaneous 

Shipments 


Boxes of good elements or plates should be shipped as 
“Lead Battery Plates.” 

Boxes of worn-out plates should be shipped as “Scrap 
Lead.” 


2 





How to Pack for Shipment 


Boxes of jars should be shipped as “Rubber Battery 
Jars”; covers and rubber separators as “Rubber Goods.” 

Empty trays should be shipped as “Empty Wood Crates.” 

The foregoing briefly covers the principal features of 
careful packing, and failure to observe these suggestions or 
good substitutes for them almost invariably entails heavy Caution 
loss and damage in transit. Claims against the carrier in 
such instances can rarely be successfully pressed to settlement 
because the carrier can readily establish the fact that the 
damage is due to improper packing. 


3 


Form 1113 M—4-’14 3500 








f 





























































Lead Burning 

The joints between plate lugs and straps and the cell to 
cell connections in vehicle batteries are usually made by melt¬ 
ing the parts to be joined and forming an integral weld. The 
process is called “ lead burning,” and is carried out either 
with a hydrogen flame or with an arc burning outfit. The 
hydrogen flame makes a quicker and neater job and is, there- 
fore, generally used where burning is done on any consider¬ 
able scale. 

In all lead burning, absolutely clean surfaces are essential 
to good workmanship. Lead is soft and very readily cleaned 
with a scraper or file. In the case of a battery which has 
had electrolyte in it, the surfaces to be burned should first be 
wiped over with ammonia or soda solution, applied with a 
piece of waste, and then allowed to dry before scraping. The 
acid is thus neutralized and removed. 

BURNING WITH THE HYDROGEN FLAME 

In assembling plates into groups, the top of the plate lug 
should be melted until it welds with the sides of the strap 
hole, and extra lead, melted and run off from a piece of 
“burning strip,” then introduced to fill the joint flush. In 
case the joint appears to be getting so hot that there is dan¬ 
ger of lead running away, burning should be started on 
another plate, so as to give the first one a chance to cool off 
before finishing. 

In burning connectors on pillar straps, the connector 
should be tapped into position so as to be a tight fit on the 
post before burning is started. Should the post project into 
the connector too far, it should be trimmed off, since the 
weld should be about Y inch deep. The top of the post 
should be melted first and then fused to the walls of the con¬ 
nector hole; after that, lead from a piece of burning strip can 
be run in until the joint is flush. 

In the case of butt joints, as between the ends of strap 
connectors, from ]/% to % inch space should be left between 
the points to be joined, so that the joint will go all the way 
through. Additional lead should not be introduced until the 
two ends are melted through to the bottom. Some soit ot 

1 


Cleaning 

Surfaces 


Assembling 

Groups 


Burning on 
Connectors 


Butt Joints 







Manual of “JExifte" Batteries in Electric Vehicles 


“Rtfl-Downs” 


Hydrogen 

Generator 


Parts 


mould is required for this type of joint to keep the melted 
lead from running off. Asbestos or clay may be used, or 
simply a thin sheet of metal under the joint with nuts or 
other pieces of iron laid on each side. 

Great care must be used to avoid “run-downs”—bits of 
molten lead running down below the joint—which are apt to 
cause short circuits in the cells. After burning, groups 
should be carefully inspected and any such “run-downs ” 
removed. This applies both to assembling of groups and to 
burning on connectors. 

Hydrogen gas for producing the hydrogen flame may be 
obtained in tanks, but the capacity of these is limited, and 
where much burning is done the 'hydrogen generator, de¬ 
scribed below, is generally used. 



The complete hydrogen generator outfit supplied by The 
Electric Storage Battery Company consists of the following 
parts: 


2 































Lead Burning 


1 hydrogen generator for producing the gas. 

1 water bottle for cleaning the gas and preventing the pos¬ 
sibility of the flame getting back into the generator. 

1 air pump for supplying air to the flame.* 

1 air tank for equalizing the air pressure.* 

1 blowpipe and set of tips for burning. 

1 burner’s tee for mixing gas and air. 

1 length of 150 feet of T 5 S inch hose (soft rubber tubing); 
this to be cut in various lengths according to the most con¬ 
venient arrangement. 

Generators are of two sizes, designated as follows; 15 x 
15 inches and 18x18 inches. (The former is generally used 


for vehicle battery work.) 

The material necessary for charging each size is as follows; 


Size of Generator 

Zinc 

Water 

Vitriol 

15x15 ins. 

50 lbs. 

9 gals. 

2 gals. 

18 x 18 ins. 

75 lbs. 

12 gals. 

3 gals. 


In preparing the generator outfit for use, connect up as 
shown in the above cut, taking care that the hose from the 
generator is connected to the nipple of the water bottle marked 
“L.” Have the water bottle from one-half to two-thirds full 
of water and immersed in a pail of cold water up to its neck, as 
shown in the drawing. Replace water in pail whenever it 
becomes warm. Have stop cock ‘ N closed. Put the re¬ 
quired amount of zinc, which has been broken up into pieces 
small enough to enter the opening at C, into the lower 
reservoir. Put on the cap “X” and fasten down with the 
screw clamp “D,” being sure that the rubber drainage stopper 
at “H” is well secured in place. Pour the proper amount of 
water for the size of the generator in use, as shown in the table 
above, into reservoir “A”; then add in the same reservoir the 
required amount of “oil of vitriol, the greatest care being 
taken to prevent its splashing out. The water must always he 
poured before the vitriol . When filling, stand on a box or 


*If there is an available supply of air under pressure, it can used and ihe 
pump and tank omitted. The pressure required being but about two t2) pounds 
per square inch, a reducing valve will in most cases be necessary. 


3 


Sizes 

Materials 


Operation 











Manual of “lExi^C” Batteries in Electric Vehicles 


platform which brings the top of the generator to the waist 
line. If burned by vitriol, apply oil, not water. 

In running the hose from “K” to “N,” so arrange it that 
there will be no low points for water of condensation to collect, 
or, in other words, this hose should drain back at every point 
into the water bottle. If, however, water should collect in the 
hose to such an extent as to interfere with the flame and it can¬ 
not be readily drained off, proceed as follows: Kink the hose 
between “T” and “U” and detach it from “K”; close the stop 
cock at “W” and pump until a strong pressure is obtained in 
the tank; then close the stop cock at “V,” opening those at 
“S" and “N,” and finally quickly open at “W”; the pressure 
in the air tank will then force the water out of the hose. 

The length of the hose from “T” to “U” should not be 
excessive, as the mixing cocks at “S” and “N” should always 
be within reach of the man who is handling the flame. 

To prepare the flame for burning, close the air cock at 
“S” and open wide that at “N,” hold a lighted match or candle 
to the gas until it burns, then add air and adjust the gas cock 
slowly, turning toward the closed position, until the flame 
when tried on a piece of lead melts the metal and leaves a clean 
surface. 

The burning tip to be used depends upon the nature of 
work to be done; in practically all vehicle battery work the 
tip with a medium hole is suitable. 

Replenish the zinc every few days, keeping it up to the 
prescribed amount. 

When a charge is exhausted or the generator is to be laid 
up for the night, the old solution should be drawn off before 
making up a new charge, and the generator thoroughly 
washed out by flushing with water poured into the upper 
reservoir “A.” If laid up for the night, the new charge 
should not be put in until the generator is used again. To 
empty a generator, first pull off the hose at the nipple “K”;‘ 
then the hose at the nipple “E,” and finally the rubber plug 
at “H.” Care should be taken not to allow the solution to 
splash on anything and not to dump it where it will damage 
cement, asphalt or wood flooring or walks. If run into a drain 

4 







Lead Burning 


should be thoroughly flushed with water immediately after¬ 
wards. 

It solution is spilled where not intended, its action can 
• ’< stopped by using baking soda, washing soda or ammonia. 

BURNING WITH THE ARC BURNING OUTFIT 

he advantage of the so-called “arc” burning lies 

' convenience, since the battery being worked upon is 
used as a source of current for the operation, rendering 
further accessory apparatus unnecessary. This outfit, as sup¬ 
plied by I he Electric Storage Battery Company consists Parts 
of the following parts: Carbon holder with cable, clamp 
and % inch carbon rods. 

Although called the “Arc” Burning Outfit, more satis¬ 
factory results can be obtained by using the heated carbon 
like a soldering iron, without actually drawing an arc. 

As stated above, the battery to be burned is usually 
used as the source of current. From two to four cells are 
required, the former when the battery is fully charged, the 
latter when it is pretty well discharged. If it is completely 
discharged, an outside source must be used, and for this pur¬ 
pose a six volt “sparking” set is suitable, one terminal being 
connected to the connection to be burned, the other to the 
cable of the burning tool. The number of cells chosen should 
be sufficient to heat the carbon to at least a bright cherry 
red while it is in contact with the joint. A little experience 
will soon demonstrate a satisfactory degree of heat. The 
cable is connected by means of the clamp to a cell in the 
battery the required number of cells away from the joint to 
be burned, and either positive or negative to it. Care should 
be taken that good contact is made by the clamp, the lead 
being scraped thoroughly clean before the connection is 
made. The carbon should be sharpened to a long point like 
a lead pencil and should project not more than 3 inches from 
the holder. The latter should be cooled off occasionally by 
plunging it, carbon and all, into a pail of water. After being 
used for a short time, it will be found that the carbon will not 
heat properly, due to a film of scale formed on the surface. 

5 






^ ,d ** deaDed ° ff Wi ' h 3 knife or Me. as occasion 

'V :r ' , he f*T of hvdrc « en darae burning, additional lead 

-he P^ a t 3 U t ,0mt ^ ^ ** 3dded Umil the meta ' of 
Zll^ . J ° lned 1135 melted - The carbon should be 
mot ed around to insure a solid joint at all points. 

. ‘ -.'-- :r S P*llar strap connections, the process is 
rendered eas,«-and the results more satisfactorv 

ampened asbestos or clay be moulded around the outside of 
the connector. 01 




14—3500 


6 





























































